Systems, methods and apparatus for providing comparative statistical information for a plurality of production facilities in a closed-loop production management system

ABSTRACT

For each of a plurality of production facilities, a series of operations is performed. For each of a plurality of batches of a concrete mixture produced at the respective production facility based on a formulation, a first difference between a measured quantity of cementitious and a first quantity specified in the formulation is determined. A first standard deviation is determined based on the first differences. For each of the plurality of batches, a second difference between a measured quantity of water and a second quantity specified in the formulation is determined. A second standard deviation is determined based on the second differences. A first benchmark is selected from among the first standard deviations, and a second benchmark is selected from among the second standard deviations. An amount by which costs may be reduced by improving production at the production facility to meet the first and second benchmarks is determined.

This application is a Division of U.S. application Ser. No. 14/139,734filed Dec. 23, 2013 which is a Continuation-In-Part of PCT/US2013/041661filed May 17, 2013, which claims priority from U.S. ProvisionalApplication No. 61/648,682, filed May 18, 2012, and aContinuation-In-Part of PCT/US2013/022523 filed Jan. 22, 2013, whichclaims priority from U.S. Provisional Application No. 61/589,640, filedJan. 23, 2012, the contents of each of which are incorporated herein byreference.

TECHNICAL FIELD

This specification relates generally to systems and methods for managinga production system, and more particularly to systems and methods forproviding comparative statistical information for a plurality ofproduction facilities in a production management system.

BACKGROUND

In many industries, consumers order a product based on a specification,and subsequent to their order, the product is manufactured based on aformulation that specifies a plurality of components and a particularmethod, procedure, or recipe to be followed. Once the product is made,it is shipped by the producer to the consumer. In such industries wherean order is placed prior to manufacturing, orders are based on expectedcharacteristics and costs of the product. When the product is made at alater date, it is important that the product be made and deliveredaccording to the expected characteristics and costs.

In practice, however, changes often occur during the manufacturing andshipping process due to a variety of factors, such as an unavailabilityof components, a failure to include the correct quantity of a componentspecified in the recipe, or the addition of a component that is notlisted in the formulation. Such changes may occur due to human error,either accidental or deliberate, or due to malfunction of a deviceinvolved in the production system, or due to unforeseen events.Furthermore, a component specified in the formulation may be incorrectlybatched, or knowingly or unknowingly replaced with assumed equivalentcomponents because the raw materials are not available, or for otherreasons. One well known example is the use of either sucrose or highfructose corn syrup in soft drinks. Typically, during production of asoft drink, one of these two sweeteners is selected and used dependingupon the cost and availability of the sweetener at the time when thesoft drink product is manufactured.

Similar practices are used in the ready mix concrete industry. A givenmixture of concrete, defined by a particular formulation (specifyingtypes of components and quantities thereof), may be produced differentlyat different production facilities and/or at different times, dependinga variety of factors. For example, the types and quantities of cementand Pozzolanic cementitious materials, chemicals, different types ofaggregates used often varies between batches, due to human error, or forreasons which may be specific to the time and location of production.Some components may not be available in all parts of the world, acomponent may be incorrectly batched, components may be replaceddeliberately or accidentally, etc. Furthermore, in the ready mixconcrete industry, it is common for changes in the mixed composition tooccur during transport of the product. For example, water and/orchemicals may be added due to weather, or due to the length of timespent in transit to the site where the ready mix concrete is poured.Changes to a mixture may also occur during the batching process. Forexample, an incorrect amount of a critical component such as water orcementitious may be added. Similarly, an incorrect amount of fly ash orother pozzolans, such as slag, may be used to make the cementitiousportion.

Due to the reasons set forth above, a customer often receives a productwhich differs from the product ordered. The quality of the product maynot meet expectations. Furthermore, any change made to a product mayimpact the producer's cost and profits.

In addition, in many industries, various activities important to aproducer's business, such as sales, purchasing of raw materials,production, and transport, are conducted independently of one another.The disjointed nature of the sales, purchasing of raw materials,production, and transport creates an additional hindrance to theproducer's, and the customer's, ability to control the quality and costof the final product.

Accordingly, there is a need for improved production management systemsthat provide, to producers and to customers, greater control overvarious aspects of the production system used to produce a product, andthereby provide greater control over quality and costs.

SUMMARY

In accordance with an embodiment, a production management system isprovided. The production management system is used in the production ofa product made from a formulation specifying a mixture of individualcomponents, where the customer orders the product prior to itsmanufacture. System and methods described herein allow a user to managecosts, and the quality of the product, from the point of order, throughthe production process, transport of the product, and delivery of theproduct to the customer. In one embodiment, a master database modulecommunicates with the sales, purchasing, manufacturing and shippingsystems to monitor and control costs and quality of the product atvarious stages in the sales, production, and delivery cycles.

In one embodiment, systems used for sales, purchasing of raw materials,manufacturing of the product, and shipping of a product are tiedtogether to allow for the management and control of cost and quality ofthe product. Systems and methods described herein allow for differentownership of different data while allowing others to use the data so asto perform their function. Thus, a user may own the mixture data butallow the manufacturer to use the mixture data in order to make theproduct. Such ownership is accomplished by having a single gateway toadd data to the system and by using a single master database.

By using a single master database which stores all of the data relatingto the mixture, the components to make the mixture, the method to makethe mixture, specifics about the products to include its costs, methodsof shipment as well as costs associated with each one of these items,quality and costs are managed during production.

Furthermore, changes made at any point during the manufacturing processare transmitted to the master database so that a record is maintained onthe product. This allows real time costs and real time quality controlof the product. Thus, variations are minimized between budget goals andoperations, both theoretically and actually.

In addition, alerts may be issued when the actual values vary from thetheoretical values. Thus, if one component is replaced with anequivalent, the master database is notified and an alert may begenerated if the replacement component is not within specifiedtolerances. Alternatively, if one or more components are batched in themanufacturing process in amounts exceeding specified tolerances ascompared to the target, theoretical amounts for each component, then analert may be issued.

By tying together the systems used for sales, purchasing of componentsand raw materials, maintaining formulations of mixtures, production ofthe mixtures and products and the shipping of the products, through amaster database, improved management of quality and costs may beachieved.

Actual and theoretical data may be captured and stored in the masterdatabase. For example, statistical data for each batch produced at aparticular production facility may be generated and stored. Comparisonsbetween theoretical and actual values are made and alerts are generatedwhen the actual falls outside the tolerances set by the theoretical.Such alerts are done in real time because each of the separate unitsused for purchasing, manufacturing and transport provide feedback to themaster database.

In another embodiment, comparative statistical information may also begenerated for a plurality of production facilities, and benchmarks maybe established in order to provide information that may be used by aproducer to improve the efficiency of one or more production facilities.

In accordance with an embodiment, a quality control and cost managementsystem can be defined as comprising: a database module having storedtherein a concrete recipe, a first tolerance and a second tolerance, thefirst tolerance associated with an informational alert and the secondtolerance associates with an actionable alert; an input module incommunication with the database module and transmitting the concreterecipes, the first tolerance and the second tolerance to the databasemodule; a production module in communication with the database module,the production module associated with a concrete production facilitythat makes a concrete mixture based on the concrete recipe andtransmitting the concrete mixture to the database module; a comparativemodule in communication with the database modules, comparing theconcrete mixture to the concrete recipe, determining if the concretemixture meets or exceeds the first tolerance and determining if theconcrete mixture meets or exceeds the second tolerance; and an alertsmodule in communication with the comparative module, generating theinformational alerts if the concrete mixture meets or exceeds the firsttolerance, and generating the actionable alert if the concrete mixturemeets or exceeds the second tolerance. In another embodiment, thedatabase module, the comparative module and the alerts module are allhoused in a single, master module at a single location. Suitably, thesingle master module is a first computer processing unit at a firstlocation.

In another embodiment, the input module is housed in a second computerat a second location. The production module may be housed in a thirdcomputer at the concrete ready-mix facility.

In another embodiment, there is a single database module which housesthe plurality of concrete recipes, a plurality of first tolerances and aplurality of second tolerances.

In another embodiment, there are a plurality of production modules eachof which is associated with a different production facility.

In another embodiment, there is a single comparative module and a singlealerts module. In another embodiment, each of the modules is a computer.

In one embodiment, the quality control management system employs aquality control management method comprising: inputting to a database aconcrete recipe, a first tolerance for generating an informational alertand a second tolerance for generating an actionable alert; making aconcrete mixture based on the concrete recipe; inputting to the databasethe concrete mixture; comparing the concrete mixture to the concreterecipe; determining if the concrete mixture meets or exceeds the firsttolerance; determining if the concrete mixture data is within the secondtolerance; generating the informational alert if the concrete mixturedata is not within the first tolerance; and generating the actionablealert if the concrete mixture data is not within the second tolerance.

In one embodiment, the formulation for the concrete mixture includesdetailed specifics about proposed ingredients, proposed amounts of theproposed ingredients, and proposed costs of the proposed ingredients.

In another embodiment, the formulation for the concrete mixture includesdetailed specifics about actual ingredients, actual amounts of theactual ingredients and actual costs of the actual ingredients.

In another embodiment, the comparing step comprises comparing the actualingredients to the proposed ingredients, comparing the actual amounts ofthe actual ingredients to the proposed amounts of the proposedingredients, and comparing the actual costs of the actual ingredients tothe proposed cost of the proposed ingredients.

In accordance with another embodiment, a method of managing a productionsystem is provided. For each of a plurality of production facilities, aseries of actions is performed. For each of a plurality of batches of aconcrete mixture produced at the respective production facility based ona formulation, a first difference between a measured quantity ofcementitious and a first quantity specified in the formulation isdetermined. A first standard deviation is determined based on the firstdifferences. For each of the plurality of batches, a second differencebetween a measured quantity of water and a second quantity specified inthe formulation is determined. A second standard deviation is determinedbased on the second differences. The first and second differences may beexpressed as a percentage or as a real number, for example. A firstbenchmark is selected from among the first standard deviations, and asecond benchmark is selected from among the second standard deviations.An amount by which costs may be reduced by improving production at theproduction facility to meet the first and second benchmarks isdetermined.

In one embodiment, the formulation is stored at a master databasemodule, and a localized version of the formulation is provided to eachrespective production facility.

In another embodiment, the plurality of production facilities aremanaged by a producer. The producer is allowed to access, via a network,in real time, a page showing the first differences, the seconddifferences, the first benchmark, the second benchmark, and the amountby which costs may be reduced.

In another embodiment, for each of the plurality of productionfacilities: a first percentage value equal to first difference dividedby the first quantity specified in a formulation is determined, and afirst standard deviation is determined based on the first percentagevalues. A second percentage value equal to second difference divided bythe second quantity specified in a formulation is determined, and asecond standard deviation is determined based on the second percentagevalues.

In another embodiment, a generalized benchmark is determined based onthe first and second benchmarks. An amount by which costs may be reducedby improving production at the production facility to meet thegeneralized benchmark is determined.

In accordance with another embodiment, a method is provided. Aformulation associated with the product, the formulation specifying aplurality of components and respective quantities required to producethe product, is transmitted to a production facility, in response toreceiving an order for a product from a customer. Data relating to theproduct produced at the production facility is received, in real time.The data is compared, in real time, to at least one pre-establishedtolerance. An alert is transmitted, in real time, to the customer if thedata is not within the pre-established tolerance.

In one embodiment, the product is delivered to a site specified by thecustomer.

In another embodiment, a difference between a quantity of a componentspecified in the formulation and an actual quantity of the component inthe product produced is determined. A determination is made as towhether the difference is within the tolerance.

In another embodiment, a difference between a cost of a componentspecified in the formulation and a cost of the component in the productproduced is determined. A determination is made as to whether thedifference is within the tolerance.

In another embodiment, a method of determining a measure of concretestrength performance quality for concrete produced at a productionfacility is provided. For each of a plurality of batches of concreteproduced at a production facility, a first difference between a measuredquantity of cementitious and a first quantity specified in a formulationis determined. A first standard deviation is determined based on thefirst differences. For each of the plurality of batches, a seconddifference between a measured quantity of water and a second quantityspecified in the formulation is determined. A second standard deviationis determined based on the second differences. A measure of concretestrength performance quality for the production facility is determinedbased on the first standard deviation and the second standard deviation.A measure of a cost of adjusting the formulation is determined based onthe measure of concrete strength performance quality.

In accordance with another embodiment, a system comprises a memory andat least one processor. The processor is configured to perform a seriesof actions. For each of a plurality of production facilities, theprocessor determines, for each of a plurality of batches of a concretemixture produced at the respective production facility based on aformulation, a first difference between a measured quantity ofcementitious and a first quantity specified in the formulation. Theprocessor also determines a first standard deviation based on the firstdifferences. The processor further determines, for each of the pluralityof batches, a second difference between a measured quantity of water anda second quantity specified in the formulation. The processor determinesa second standard deviation based on the second differences. Theprocessor selects a first benchmark from among the first standarddeviations, and a second benchmark from among the second standarddeviations, and determines an amount by which costs may be reduced byimproving production at the production facility to meet the first andsecond benchmarks.

These and other advantages of the present disclosure will be apparent tothose of ordinary skill in the art by reference to the followingDetailed Description and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A illustrates a product management system in accordance with anembodiment;

FIG. 1B shows an exemplary menu that may be presented to a customer inaccordance with an embodiment;

FIG. 1C is a flowchart of a method of managing a production system inaccordance with an embodiment;

FIG. 2 is a flowchart of a method of producing a mixture in accordancewith an embodiment;

FIG. 3 is a flowchart of a method of handling an order received from aproduction facility in accordance with an embodiment;

FIG. 4 illustrates a method of responding to an alert when a productionfacility replaces an ingredient with a known equivalent, in accordancewith an embodiment;

FIG. 5 is a flowchart of a method of responding to an alert indicating adifference between a batched quantity and a specified quantity inaccordance with an embodiment;

FIG. 6 is a flowchart of a method of managing transport-related data inaccordance with an embodiment;

FIG. 7A shows a production management system in accordance with anotherembodiment;

FIG. 7B shows a production management system in accordance with anotherembodiment;

FIG. 7C shows a production management system in accordance with anotherembodiment;

FIG. 8 illustrates a system for the management of localized versions ofa mixture formulation in accordance with an embodiment;

FIG. 9 is a flowchart of a method of generating localized versions of amixture formulation in accordance with an embodiment;

FIG. 10 shows a mixture formulation and several localized versions ofthe mixture formulation in accordance with an embodiment;

FIGS. 11A-11B illustrate a system for synchronizing versions of amixture formulation in accordance with an embodiment;

FIG. 12 is a flowchart of a method of synchronizing a localized versionof a mixture formulation with a master version of the mixtureformulation in accordance with an embodiment;

FIGS. 13A-13B comprise a flowchart of a method of managing a closed-loopproduction system in accordance with an embodiment;

FIG. 14 shows an exemplary web page that displays information relatingto purchase, production and delivery of a mixture in accordance with anembodiment;

FIG. 15 shows a production management system in accordance with anotherembodiment;

FIGS. 16A-16B comprise a flowchart of a method of producing andanalyzing a mixture in accordance with an embodiment;

FIG. 17 is a flowchart of a method of producing a formulation-basedmixture in accordance with an embodiment;

FIG. 18 is a flowchart of a method of determining a measure of concretestrength performance quality for concrete produced at a productionfacility in accordance with an embodiment;

FIGS. 19A-19B comprise a flowchart of a method of providing comparativestatistical information relating to a plurality of production facilitiesin accordance with an embodiment;

FIG. 20 shows a web page containing statistical information for aplurality of production facilities in accordance with an embodiment; and

FIG. 21 is a high-level block diagram of an exemplary computer that maybe used to implement certain embodiments.

DETAILED DESCRIPTION

In accordance with embodiments described herein, systems and methods ofmanaging a closed-loop production management system used for productionand delivery of a formulation-based product are provided. Systems,apparatus and methods described herein are applicable to a number ofindustries, including, without limitation, the food manufacturingindustry, the paint industry, the fertilizer industry, the chemicalsindustry, the oil refining industry, the pharmaceuticals industry,agricultural chemical industry and the ready mix concrete industry.

In accordance with an embodiment, a method of managing a closed loopproduction system is provided. An order relating to a formulation-basedproduct is received, wherein fulfilling the order requires production ofthe formulation-based product at a first location, transport of theformulation-based product in a vehicle to a second location differentfrom the first location, and performance of an activity with respect tothe formulation-based product at the second location. First informationrelating to a first change made to the formulation-based product at thefirst location is received, from the first location, prior to transportof the formulation-based product. Second information relating to asecond change made to the formulation-based product during transport ofthe formulation-based product is received during transport of theformulation-based product. Third information relating to the activityperformed with respect to the formulation-based product at the secondlocation is received from the second location. The first, second, andthird information are stored in a data structure, and may be displayedwith an analysis of the impact of selected information on the cost ofthe product.

In one embodiment, the processor operates within a product managementsystem comprising a plurality of modules operating at independentlocations associated with various stages of the ordering, production,transport and delivery of the product.

In accordance with an embodiment, the product is a formulation-basedproduct. In one embodiment, the product is a formulation-based concreteproduct. In other embodiments, the formulation-based product may be anytype of product that is manufactured based on a formulation. Forexample, the formulation-based product may be a chemical compound orother type of chemical-based product, a petroleum-based product, a foodproduct, a pharmaceutical drug, etc. Systems, apparatus and methodsdescribed herein may be used in the production of these and otherformulation-based products.

In another embodiment, statistical information concerning a plurality ofproduction facilities is generated and provided to a producer and/or acustomer. For each of a plurality of production facilities, a series ofactions is performed. For each of a plurality of batches of a concretemixture produced at the respective production facility based on aformulation, a first difference between a measured quantity ofcementitious and a first quantity specified in the formulation isdetermined. A first standard deviation is determined based on the firstdifferences. For each of the plurality of batches, a second differencebetween a measured quantity of water and a second quantity specified inthe formulation is determined. A second standard deviation is determinedbased on the second differences. A first benchmark is selected fromamong the first standard deviations, and a second benchmark is selectedfrom among the second standard deviations. An amount by which costs maybe reduced by improving production at the production facility to meetthe first and second benchmarks is determined.

The terms “formulation,” “recipe,” and “design specification” are usedherein interchangeably. Similarly, the terms “components” and“ingredients” are used herein interchangeably.

FIG. 1A illustrates a production management system in accordance with anembodiment. Product management system 10 includes a master databasemodule 11, an input module 12, a sales module 13, a production module14, a transport module 15, a site module 16, an alert module 17 and apurchasing module 18.

Master database module 11 may be implemented using a server computerequipped with a processor, a memory and/or storage, a screen and akeyboard, for example. Modules 12-18 may be implemented by suitablecomputers or other processing devices with screens for displaying andkeep displaying data and keyboards for inputting data to the module.

Master database module 11 maintains one or more product formulationsassociated with respective products. In the illustrative embodiment,formulations are stored in a database; however, in other embodiments,formulations may be stored in another type of data structure. Masterdatabase module 11 also stores other data related to various aspects ofproduction management system 10. For example, master database module maystore information concerning acceptable tolerances for variouscomponents, mixtures, production processes, etc., that may be used insystem 10 to produce various products. Stored tolerance information mayinclude tolerances regarding technical/physical aspects of componentsand processes, and may also include tolerances related to costs. Masterdatabase module 11 may also store cost data for various components andprocesses that may be used in system 10.

Each module 12-16 and 18 transmits data to master database module 11 bycommunication lines 21-26, respectively. Master database module 11transmits data to modules 13, 14, 17 and 18 by communication lines31-34, respectively. Each communication line 21-26 and 31-34 maycomprise a direct communication link such as a telephone line, or may bea communication link established via a network such as the Internet, oranother type of network such as a wireless network, a wide area network,a local area network, an Ethernet network, etc.

Alert module 17 transmits alerts to customers by communication line 35to site module 16.

Master database module 11 stores data inputted from modules 12-16 and18. Master database module 11 stores data in a memory or storage using asuitable data structure such as a database. In other embodiments, otherdata structures may be used. In some embodiments, master database module11 may store data remotely, for example, in a cloud-based storagenetwork.

Input module 12 transmits to master database module 11 by communicationline 21 data for storage in the form of mixture formulations associatedwith respective mixtures, procedures for making the mixtures, individualingredients or components used to make the mixture, specifics about thecomponents, the theoretical costs for each component, the costsassociated with mixing the components so as to make the product ormixture, the theoretical characteristics of the product, acceptabletolerances for variations in the components used to make the product,the time for making and delivering the product to the site and costsassociated shipping the product.

The terms “product” and “mixture” are used interchangeably herein.

Data transmitted by input module 12 to master database module 11 andstored in master database module 11 may be historical in nature. Suchhistorical data may be used by the sales personal through sales module13 to make sales of the product.

In one embodiment, sales module 13 receives product data bycommunication line 31 from master database module 11 relating to variousproducts or mixtures that are managed by system 10, the components thatmake up those products/mixtures, the theoretical costs associates withthe components, making the mixture and delivery of the mixture, timesfor delivery of the mixture and theoretical characteristics andperformance specifications of the product.

Sales module 13 may present all or a portion of the product data to acustomer in the form of a menu of options. FIG. 1B shows an exemplarymenu 55 that may be presented to a customer in accordance with anembodiment. Menu 55 comprises a list of mixtures available for purchase,including Mixture A (61), Mixture B (62), Mixture C (63), etc. Eachmixture shown in FIG. 1B represents a product offered for sale. Forexample, each mixture may be a respective concrete mixture that may bepurchased by a customer. Menu 55 is illustrative only; in otherembodiments, a menu may display other information not shown in FIG. 1B.For example, a menu may display the components used in each respectivemixture, the price of each mixture, etc.

From the menu, the customer may choose one or more products to purchase.For example, a customer may purchase Mixture A (61) by selecting aPurchase button (71). When the customer selects a mixture (by pressingPurchase button (71), for example), sales module 13 generates an orderfor the selected mixture and transmits the order by communication line22 to master database module 11. The order may specify the mixtureselected by the customer, the components to be used to make the selectedmixture, a specified quantity to be produced, the delivery site, thedelivery date for the product, etc. An order may include other types ofinformation.

In accordance with an embodiment, the customer may input a specialtyproduct into system 10. Such input may be accomplished through inputmodule 12.

Customer orders are transmitted to master database module 11. Masterdatabase module 11 uses an integrated database system to manageinformation relating to the orders, as well as the production,transport, and delivery of the ordered products. FIG. 1C is a flowchartof a method of managing a production system in accordance with anembodiment. At step 81, an order relating to a formulation-based productis received, wherein fulfilling the order requires production of theformulation-based product at a first location, transport of theformulation-based product in a vehicle to a second location differentfrom the first location, and performance of an activity with respect tothe formulation-based product at the second location. As describedabove, the customer's order is transmitted to master database module 11.Master database module receives the order from sales module 13, andstores the order.

Based on the order inputted to master database module 11, masterdatabase module 11 places a production order for production of theproduct to production module 14 by communication line 32. Productionmodule 14 is located at a production facility capable of manufacturingthe purchased product in accordance with the order.

In the illustrative embodiment, the product is a formulation-basedproduct. Thus, the product may be produced based on a formulationdefining a plurality of components and respective quantities for each ofthe components. The formulation may also specify a method, or recipe,for manufacturing the product. The production order provided to theproduction module 14 may include the mixture or product to be made, thecomponents to be used to make the mixture or product, the specificsabout the individual components, the method to make the mixture and thedelivery dates. The product is produced at the production facility andplaced in a vehicle for transport to a delivery site specified in theorder.

At step 83, first information relating to a first change made to theformulation-based product at the first location is received from thefirst location, prior to transport of the formulation-based product. Ifany changes are made to the product at the production facility,production module 14 transmits information relating to such changes tomaster database module 11. For example, a particular component specifiedin the formulation may be replaced by an equivalent component. Inanother example, a quantity of a selected component specified in theformulation may be altered. Master database module 11 receives andstores such information.

At step 85, second information relating to a second change made to theformulation-based product during transport of the formulation-basedproduct is received during transport of the formulation-based product.If any changes are made to the product during transport of the product,transport module 15 transmits information relating to such changes tomaster database module 11. Master database module 11 receives and storessuch information.

Upon arrival at the specified delivery site, the product is delivered.At step 87, third information relating to the activity performed withrespect to the formulation-based product at the second location isreceived from the second location. For example, site module 16 maytransmit to master database module 11 information indicating the time ofdelivery, or information relating to the performance of the productafter delivery.

In the illustrative embodiment, information transmitted among modules11-19, and to a producer or customer, may be transmitted in the form ofan alert. An alert may be any suitable form of communication. Forexample, an alert may be transmitted as an electronic communication,such as an email, a text message, etc. Alternatively, an alert may betransmitted as an automated voice message, or in another form.

In one embodiment, information is transmitted to master database module11 in real time. For example, strict rules may be applied requiring thatany information concerning changes to a product that is obtained by anymodule (including production module 14, purchase module 18, transportmodule 15, site module 16, etc.) be transmitted to master databasemodule 11 within a predetermined number of milliseconds.

Various embodiments are discussed in further detail below.

As described above, in some embodiments, the product is made at aproduction facility in accordance with a predetermined formulation.Production module 14 operates at the production facility and has storeddata as to the specifics of the individual components or raw ingredientson hand at the facility. FIG. 2 is a flowchart of a method of producinga mixture in accordance with an embodiment. At step 210, an order tomake a product/mixture from specified components is received. Referringto block 220, if the exact components or ingredients are in stock, theproduction facility proceeds to make the mixture/product (step 230). Ifthe production facility does not have on hand the exact componentsneeded to make the mixture/product, then the method proceeds to step 260and determines whether an equivalent component is in stock. If anequivalent component is in stock, the method proceeds to step 270. Atstep 270, production module 14 makes the product using the equivalentcomponent and alerts master database module 11 of the change. Such areplacement may change the cost of the raw materials and/or thecharacteristics of the mixture/product which is finally made.

Returning to block 260, if there is no equivalent component in stock,the production module 14 may send an order by communication line 32 tomaster database module 11 (step 240) for the specified component (or forthe equivalent component). When the order is received, production module14 makes the product (step 250).

In another embodiment, production module 14 alerts master databasemodule 11 if the method of manufacture specified in a mixtureformulation is modified. For example, a step of the method may bechanged or eliminated, or a new step may be added. Master databasemodule stores information related to the change. Master database module11 may also determine if the change is within acceptable tolerances andalert the customer if it is not within acceptable tolerances. Forexample, master database module 11 may compare the modified method tostored tolerance information to determine if the modified method isacceptable.

FIG. 3 is a flowchart of a method of handling an order received from aproduction facility in accordance with an embodiment. At step 310, anorder is received from production module 14, by master database module11. At step 320, master database module 11 places an order bycommunication line 34 to purchase module 18 to purchase the neededcomponents or raw materials. Purchase module 18 transmits bycommunication line 26 the specifics of the components that it haspurchased and the estimated delivery date to the production facility aswell as the costs associated with the component. Purchase module 18 isassociated with a raw material/component supply facility. At step 340,master database module 11 receives the specifics on the componentsactually purchased by purchase module 18.

Referring to block 350, if the components purchased (by purchase module18) are the same as the order placed, the method proceeds to step 380,and the product is shipped to the production facility. If the componentspurchased (by purchase module 18) differ from those specified in theorder, the method proceeds to block 360. Master database module 11compares the components purchased, either those replaced by theproduction facility or those purchased by the purchase module 18, tostored tolerance information (which may include tolerances regardingphysical/technical aspects of a component and/or cost tolerances).Referring to block 360, if the replacement components fall withinacceptable tolerances both for performance characteristics and cost,then production is continued and, at step 370, the order is shipped tothe production facility. If the cost or characteristics of the rawingredients fall outside acceptable tolerances, then the method proceedsto step 390. At step 390, master database 11 transmits an alert bycommunication line 33 to alert module 17 and the components are shippedto the production facility. Alert module 17 receives the alert frommaster database module 11 and, in response, transmits by communicationlines 35 an alert to the customer. As shown in FIG. 1, the alert fromalert module 17 is transmitted by communication lines 35 to site module16.

FIG. 4 is a flowchart of a method of responding to an alert inaccordance with an embodiment. Specifically, FIG. 4 illustrates a methodof responding to an alert when a production facility replaces an exactingredient with a known equivalent, in accordance with an embodiment. Atstep 410, an alert indicating an equivalent replacement is received bymaster database module 11 from production module 14. Referring to block420, a determination is made by master database module 11 whether theequivalent component is within acceptable tolerances. If the equivalentcomponent is within acceptable tolerances, the method proceeds to step430 and the product is made. Master database module 11 instructsproduction module 14 to proceed with manufacturing the mixture. If theequivalent component is not within acceptable tolerances, the methodproceeds to step 440. At step 440, and an alert is transmitted and theproduct is made. For example, an alert may be transmitted by masterdatabase module 11 or by alert module 17 to the customer.

At step 450, the variances of actual versus theoretical cost andperformance factors are stored at master database module 11.

As described above, production module 14 receives instructions frommaster database module 11, prior to production of a mixture, specifyingthe recipe and components required for producing the mixture. However,from time to time the batched amounts of each component (i.e., theamount of each component in the batch actually produced) differs fromthe amounts specified in the recipe received from master database module11 due to statistical or control factors.

When quantity variances are outside the specified tolerances, alerts aretransmitted and the actual amounts produced, and cost variances fromtarget costs, are provided to master database module 11. FIG. 5 is aflowchart of a method of responding to an alert indicating a differencebetween a batched quantity and a specified recipe quantity in accordancewith an embodiment. At step 510, an alert is received indicating adifference between a batched quantity and a specified recipe quantity.The alert typically indicates variances of actual versus theoreticalcost and performance factors. Referring to block 520, if the differencesare within acceptable tolerances, the method proceeds to step 530 andthe product is delivered. If the differences are not within acceptabletolerances, the method proceeds to step 540. At step 540, an alert istransmitted and the product is delivered. An alert may be transmitted tothe customer, for example. At step 550, the variances of actual versustheoretical cost and performance factors are stored at master databasemodule 11. In other embodiments, variances are not stored.

After production of the mixture, the production facility uses one ormore transport vehicles to transport the product/mixture from theproduction facility to the customer's site. Such transport vehicles mayinclude trucks, automobiles, trains, airplanes, ships, etc. Eachtransport vehicle is equipped with a transport module such as transportmodule 15. Transport module 15 transmits by communication line 24 tomaster database 11 information concerning the transport of theproduct/mixture. The information concerning the transport can includechanges which are made to the mixture during transport (e.g., additionof water or other chemicals), the length of travel, temperatures duringtransport, or other events that occur during transport. For example, inthe ready mix concrete industry it is common for a truck transportingthe mixture from the production facility to a delivery site to add waterand/or chemicals during the transport process. Information indicatingsuch addition of chemicals or water is transmitted to master databasemodule 11 by communication line 24. Furthermore, in the ready mixconcrete industry, measuring and recording the temperature of theconcrete during transport is advantageous for several reasons: (a) suchdata can be used to determine a maturity value per ASTM c1074; (b) suchdata, in combination with reference heat of hydration data may be usedto determine degree of hydration attained during transport; (c) thedata, in combination with reference strength and heat of hydration datamay be used to determine pre-placement strength loss due topre-hydration prior to discharge of the concrete at project site.

The transport-related information is transmitted by transport module 15to master database module 11. For example, such information may betransmitted in the form of an alert. The information is analyzed bymaster database module 11 to determine whether the changes that are madeare within acceptable tolerances. FIG. 6 is a flowchart of a method ofmanaging transport-related data in accordance with an embodiment.

At step 610, information indicating changes to a mixture duringtransport is received from a transport module. For example, masterdatabase module 11 may receive an alert from transport module 15indicating that changes occurred to a mixture during transport of themixture. Referring to block 620, a determination is made whether thechanges are within acceptable tolerances. If the changes are withinacceptable tolerances, the method proceeds to step 630. At step 630, theproduct/mixture is delivered to the customer's site. If the changes arenot within acceptable tolerances, the method proceeds to step 640. Atstep 640, an alert is transmitted to the customer and theproduct/mixture is delivered. Alerts to the customer may be issued byalert module 17, or by master database module 11. At step 650, theinformation concerning changes occurring during transport is saved atmaster database module 11. In other embodiments, the informationconcerning changes is not stored.

In the illustrative embodiment, the customer's site or location isequipped with site module 16, which transmits to master database module11, by communication line 25, information about the mixture of productthat is delivered to the site. Such information may include, forexample, information indicating the actual performance of theproduct/mixture as delivered. Master database module 11 stores theactual performance data. Master database module 11 may provide to thecustomer a report concerning various aspects of the actual productdelivered.

Site module 16 may also receive alerts from alert module 17 bycommunication line 35. In the illustrative embodiment, alert module 17is a module separate from master database module 11. However, in otherembodiments, the functions of alert module 17 may be performed by masterdatabase module 11.

Alert module 17 may also transmit final reports concerning the productsto site module 16, thereby enabling the seller and the customer a way ofmanaging the product. Feedback provided throughout the productionprocess, as illustrated above, advantageously allows the customer andthe manufacturer to manage costs and quality of the products.

The alert functions described above facilitate the process of managingproduction and costs. In response to any alert, the customer or themanufacturer has the ability to make a decision not to continue theproduction or delivery of the product because the product has fallenoutside of acceptable tolerances.

While the illustrative embodiment of FIG. 1A includes only oneproduction module, one transport module, one site module, one alertmodule, one purchase module, one input module, and one sales module, inother embodiments, a system may include a plurality of productionmodules, a plurality of transport modules, a plurality of site modules,a plurality of alert modules, a plurality of purchase modules, aplurality of input modules, and/or a plurality of sales modules. Forexample, in an illustrative embodiment, suppose that a system used by acompany in the ready mix concrete industry includes a master databasemodule 11 residing and operating on a server computer located inPittsburgh, Pa. The company's sales force may be located in Los Angeles,Calif., where the sales module 13 resides and operates (on a computer).Suppose that a sale is made in Los Angeles, and the purchase orderspecifies a site in San Francisco, Calif. Thus, master database module11 may output an order to a production module 14 which is located at aready mix production facility in the vicinity of San Francisco, Calif.Suppose further that a single production facility in the vicinity of SanFrancisco cannot handle the volume of the concrete that is needed forthe job site in San Francisco. In such a case, master database module 11may output to a plurality of production facilities, each having aproduction module 14, the necessary orders for fulfillment. Thus, thesystem includes a plurality of production modules, one in each of thevarious production facilities. The production facilities produce thespecified mixture and transport the ready mix concrete in a plurality oftrucks to the customer site in San Francisco. Each truck has a transportmodule associated therewith. Suppose that one or more of the productionmodules does not have the specific components that were specified in thepurchase order for the concrete. Thus, adjustments may be made at theproduction facility to the concrete mixes, and information concerningsuch adjustments are transmitted back to the master data base module 11.Such adjustment information may be processed in accordance with thesteps illustrated in FIGS. 3 and/or 4.

During the transport of the ready mix concrete from the variousproduction facilities, the transport modules 15 in each of the truckstransmit to the master database module 11 any changes made to themixture. The master database module 11 may then perform the methoddescribed FIG. 6. In a similar manner, master database module 11 isinformed of any changes occurring during production and, as a result,master database module 11 may perform the method described in FIG. 5.

Finally, the concrete is delivered to the customer site in San Franciscoand information concerning the delivered concrete may be transmitted tothe master database module 11. The site module 16 may also be used toprovide the master database module 11 with information relating to oneor more of the following: measurements of the actual heat of hydrationtaken from the fresh state through the hardening process, strengthcharacteristics of the concrete after it is hardened, etc.Advantageously, the feedback provided in this manner to master databasemodule 11 from the various modules enables the customer of the concretein Los Angeles to monitor, on a real time basis, the concrete poured atthe customer's construction site in San Francisco, without having tophysically be in San Francisco.

Furthermore, the customer in Los Angeles may monitor, on a real timebasis, costs associated with the concrete which is delivered to the sitein San Francisco.

Furthermore, the ready mix concrete producer may associate, in realtime, variances in one or more parameters relating to the concrete'sperformance from specified expectations, and correlate such variances toactual batched versus the expected specified recipe. These capabilitiesadvantageously allow the maintenance of consistent, low standarddeviation production batching from a mixture recipe baseline, andproduction of concrete that has a consistent strength performance with alow standard deviation.

Changes in materials may impact a producer's cost of materials (COM). Anincrease in COM can in turn impact the producer's profitability. In manyinstances, any increase (in percentage terms) in the COM results in amuch greater impact on profitability (in percentage terms). For example,it has been observed that, using ACI 318 statistical quality criteria,it can be demonstrated that each 1% cement or water variance from themix design theoretical recipe value can result in a cost impact ofaround $0.2 to $0.4 per cubic yard. Since such variances can typicallyrange from 2% to 10%, the cost impact may range from $0.4 to $10 percubic yard annually. This cost impact is a very large percentage of theaverage profit of a producer in the ready mix concrete industry, whichis on the order of $1/cubic yard.

Advantageously, the integrated production management system and methoddescribed herein enables a producer to manage the overall productionsystem for ready mix concrete, and allows greater control over changesthat may impact the producer's costs (and profits). The integratedproduction management system and method described herein also provides acustomer increased control over the customer's construction site.

For convenience, several examples relating to the ready mix concreteindustry are described below.

Concrete Construction & Manufacturing/Production Examples

Examples are provided for three different market segments:

A. Ready Mix Concrete

B. Contractors

C. State Authorities

Closed Loop Solutions (CLS) Overview

Set forth below is a discussion of a closed loop solution (CLS) inaccordance with an embodiment. Each operation has a set of theoreticalgoals and obtained physical or actual results.

Practically all operational IT architectures include a collection ofdisparate information systems that need to work together.

CLS is an information technology solution that enforces:

Data Integrity across linked or associated disparate information systems(Ready Mix Example: Mix costs & formulae to have data integrity or bethe same across mix management, sales, dispatch, batch panels, andbusiness systems)

Closed Loop Data Integrity, meaning that the operations' goals and itsactual physical results match within tolerances (concrete batch & mixBOMs (Bill of Materials) closely match)

Four Types of CLS for Different Market Segments

-   -   I. Ready Mix Producers: Closed Loop Integration (CLI):        -   1) CLI has been implemented as a CLS application for many            Ready Mix Producers in the US and Canada.        -   2) CLI applications are real-time, two-way interfaces with            production systems        -   3) One of the main purposes of CLI is to enforce data            integrity between batches in trucks and parent mix designs;            CLI closes the loop between the mix management and            production cycles.    -   II. Ready Mix Producers: Closed Loop Sales Management (CLSM):        -   1) CLSM is a CLS application for Ready Mix Producers in the            US and Internationally.        -   2) One of the main purposes of Closed Loop Sales Management            is a project-based workflow for the industry sales process,            tracking actual versus target profitability, This            application closes the loop between actual and target            profitability factors. One benefit is maximization of            profitability.    -   III. Contractors: Closed Loop Quality & Cost:        -   1) The solution for the Contractor market segment is similar            to the Closed Loop Quality application, except that it also            includes concrete delivered cost management        -   2) One of the main purposes of Closed Loop Quality & Cost is            a real time enforcement of placed concrete obtained specs            and performance to the applicable project specs, plus            monitoring placed versus as-purchased cost—This application            closes the loop between both the delivered versus specified            project concrete performance and cost.    -   IV. State Authorities: Closed Loop Quality:        -   1) This solution is intended for the Authorities market            segment as a modification of the CLI production driven Ready            Mix application        -   2) One of the main purposes of Closed Loop Quality is a real            time enforcement of placed concrete obtained specs and            performance to the applicable project specs. This            application closes the loop between the delivered versus            specified project concrete performance.

Set forth below are several application examples.

[A] Ready Mix Concrete Producers—CLS TYPE: Closed Loop Integration forReal Time, Production Level, Consolidated Mix Management

-   -   I. Ready Mix Needs Include:        -   1) Consolidate critical mix, cost, and quality data in a            single database        -   2) Minimize quality issues        -   3) Utilize materials efficiently        -   4) Real time information visibility—customized by user            profile    -   II. Ready Mix Economics & its Management:        -   1) 50% to 70% of cost of business (COB) is cost of materials            (COM)        -   2) A 1% increase in COM can translate to more than a 10%            profitability drop        -   3) Thus, production level materials management is important            to profitability.

TABLE 1 Item per Cyd Net Profit % 5.0% Price $85.00 Cost of Business(COB) $80.75 Net Profit $4.25 Cost of materials (COM) as % of 55.0% COBCOM $44.41 1% increase in COM $0.44 Change in COB $0.44 Change in Netprofit ($0.44) % change in net profits per % COM −10.5%

-   -   -   Table 1 shows the relationship between COM and            profitability.

    -   III. To Meet Quality, Materials Utilization, and Information        Visibility Needs:        -   1) Optimize mixes to performance and cost goals in a            consolidated database using mix optimization tools.        -   2) Implement closed loop integration (CLI) for the            production level management of optimized mixes; may use            alerts application for alert notification of            out-of-tolerance batches.        -   3) Use CLI to ship concrete to mix baselines for            implementing production level, real time cost and quality            management. The CLI system in effect uses mixes as a            budgetary tool for both quality and cost control.

[B] Contractors—CLS Type: Closed Loop Cost & Quality

Table 2 illustrates advantages of real time, consolidated costs andquality management.

TABLE 2

-   -   I. Contractor Concrete Related Needs:        -   1) Consolidate aspects of concrete related data across all            projects in a single database.        -   2) Ensure obtained quality meets specifications in order to            minimize quality issues and avoid project delays        -   3) Track & match up contracted volume & cost versus actual            delivered volumes & costs        -   4. Real time information visibility—customized by user            profile    -   II. Basic Contractor Economics:        -   1) Concrete cost and quality related schedule delay can            amount to around 16% in profit loss.        -   2) Thus, production level concrete quality and cost            management are important to contractor profitability    -   III. Closed Loop Solution to Meet Quality, Cost Management, and        Information Visibility Needs:        -   1) Implement Closed Loop Cost & Quality (CLCQ) for the real            time management of obtained versus a) specified performance            and recipe factors, b) Actual versus budgeted cost and            volume factors; use an alert system for alert reporting &            notification of out-of-tolerance monitored variables.        -   2) For each project, consolidate quality & engineering team,            tests, concrete deliveries & poured volumes, cost, project            mix designs and specs, project documents, in a single            unified database; do this across all of the contractor's            projects in one or more countries—makes possible sharing and            learning cross project experience        -   3) Use CLCQ to maintain quality, enforce meeting specs in            real time, enforce budgetary cost & volume goals, and create            real time, production level visibility including alerting            reports.

Contractor Concrete Economics

-   -   1. 10% to 20% of a project cost is concrete cost; in some        regions/countries this number may be close to 20%    -   2. Since contractor margin is on the order of 1% to 5%, a 1%        change in concrete cost may result on average in about a 8%        profitability drop    -   3. Additionally, it is import to avoid schedule slippage due to        quality issues:        -   1. Each delay day may represent roughly 0.2% to 1% of total            project cost—assume 0.2%        -   2. Each delay day due to concrete quality for a $100 mil            project may cost $200,000, or roughly an 8% drop in            profitability    -   4. Concrete cost and quality schedule delay may total to around        16% in profit loss.    -   5. Thus, production level quality and cost management are        important to contractor profitability, and the related cost        factors can be managed by a closed loop production system

[C] State Authorities—CLS TYPE: Closed Loop Quality For Real Time,Consolidated Concrete Quality Management

-   -   I. State Authority Key Concrete Related Needs:        -   1) Consolidate all aspects of concrete related data across            all projects in a single database including mix            specifications and designs, batch data, and test data, as            well as the required QC/QA plan        -   2) Make possible data access, input, and sharing cross            projects, and by project-based entities        -   3) Ensure obtained quality and performance meet            specifications in order to minimize quality issues and avoid            project delays        -   4) Track & match up contracted costs & volumes versus actual            values        -   5) Real time information visibility—customized by project &            user profile    -   II. State Authority Economics—Costs of poor quality and reduced        longevity:        -   1) Assume: $100 mil structure; 30,000 m3 concrete @ $100/m3            delivered        -   2) Concrete quality related schedule delay costs may amount            to $70,000/delay day        -   3) Poor quality future repair costs may amount to $120,000            per 1% increase in strength CV        -   4) If the building service life is reduced by one year due            to poor quality, then a revenue loss of around $1.25 mil.            may result        -   5) Thus, production level, real time quality and cost            management is important to the owner economics        -   6) These significant cost factors may be managed by the            closed loop system    -   III. To meet quality, cost management, and information        visibility needs:        -   1) For each project, consolidate concrete production            volumes, project mix designs and specifications, and tests            in a single database. Also, include the QA/QC plan        -   2) Make possible data access, input, and sharing across            projects. Restrict access by project and user profile.            Include: State officials, Engineers/Architects, Contractors,            Test Labs, and Ready Mix Producers        -   3) Implement Closed Loop Quality (CLQ) for the real time            management of obtained versus specified performance and            recipe factors; use an alert system for alert notification            of out-of-tolerance batches. Reconcile tests against QC/QA            plan.        -   4) Create real time, production level visibility including            alerting reports.

State Authority Concrete Economics Assume a $100 Mil Structure Requiring30,000 m3 Concrete @ an Average of $100/m3 Delivered.

-   -   1. Suppose that:        -   1) The owner wishes to amortize the $100 mil cost during a            10-year period, which amounts to a monthly rate of $833,333,            and wishes to lease the building for the same amount        -   2) The owner takes a 30 year mortgage @ 5% interest            amounting to a monthly payment of $535 k.        -   3) This leaves a monthly cash flow of around $300 k, or $3.6            mil/yr    -   2. Poor Quality Cost Factors include:        -   1) Each delay day may result in an opportunity cost of            roughly $70,000, or around 2% of annual cash flow        -   2) If poor quality goes unnoticed, and is repaired at a            later date, each 1% increase in the 28-day strength            coefficient of variation from its ACI 318 design base may            result in future repair costs of $120 k, or around 7% of the            annual cash flow        -   3) If poor quality goes unnoticed, and is not treated, each            one year reduction in the service life may amount to $3.6 in            lost revenues. Annualized over the first 10 years, this            changes the monthly cash flow to around a loss of ($60,000)    -   3. Concrete poor quality costs without a reduction in the        service life can amount to around 9% of cash flow; with service        life reduction, the cash flow can turn negative.    -   4. Thus, production level quality management is important to the        owner economics, and the related cost factors can be managed by        the closed loop system

In accordance with another embodiment, a mixture formulation ismaintained by master database module 11. Localized versions of themixture formulation intended for use at respective production facilitiesare generated, stored, and provided to the respective productionfacilities, as necessary. At a respective production facility, themixture is produced based on the localized version of the mixtureformulation.

FIG. 7A shows a production management system 700 in accordance withanother embodiment. Similar to product management system 10 of FIG. 1A,product management system 700 includes a master database module 11, aninput module 12, a sales module 13, a production module 14, a transportmodule 15, a site module 16, an alert module 17, and a purchase module18.

A localization module 19 resides and operates in master database module11. For example, master database module 11 and localization module 19may comprise software that resides and operates on a computer.

Localization module 19 generates one or more localized versions of amixture formulation for use at respective production facilities where amixture may be produced. Localization module 19 may, for example, accessa mixture formulation maintained at master database module 11, analyzeone or more local parameters pertaining to a selected productionfacility, and generate a modified version of the mixture formulation foruse at the selected production facility. Localization module 19 maygenerate localized versions of a particular mixture formulation for oneproduction facility or for a plurality of production facilities. Forexample, master database module 11 may generate localized versions of amixture formulation for every production facility owned or managed by aproducer. Likewise, localization module 19 may generate localizedversions of selected mixture formulations maintained by master databasemodule 11, or may generate localized versions for all mixtureformulations maintained by master database module 11.

FIG. 7B shows a production management system 702 in accordance withanother embodiment. Similar to product management system 10 of FIG. 1A,product management system 702 includes a master database module 11, aninput module 12, a sales module 13, a production module 14, a transportmodule 15, a site module 16, an alert module 17, and a purchase module18. In the embodiment of FIG. 7B, localization module 19 is separatefrom master database module 11 and is connected to master databasemodule 11 by a link 41. For example, master database module 11 mayreside and operate on a first computer and localization module 19 mayreside and operate on a second computer remote from master databasemodule 11. For example, localization module 19 may reside and operate ona second computer located at a production facility. Localization module19 may communicate with master database module 11 via a network such asthe Internet, or via another type of network, or may communicate via adirect communication link.

FIG. 7C shows a production management system 703 in accordance withanother embodiment. Product management system 703 includes a masterdatabase module 11, an input module 12, a sales module 13, a productionmodule 14, a transport module 15, a site module 16, an alert module 17,a purchase module 18, and a localization module 19. Modules 11-19 areconnected to a network 775. Modules 11-19 communicate with each othervia network 775. For example, various modules may transmit informationto master database 11 via network 775.

Network 775 may comprise the Internet, for example. In otherembodiments, network 775 may comprise one or more of a number ofdifferent types of networks, such as, for example, an intranet, a localarea network (LAN), a wide area network (WAN), a wireless network, aFibre Channel-based storage area network (SAN), or Ethernet. Othernetworks may be used. Alternatively, network 775 may comprise acombination of different types of networks.

FIG. 8 illustrates a system for the management of localized versions ofa mixture formulation in accordance with an embodiment. In theillustrative embodiment of FIG. 8, master database module 11 compriseslocalization module 19, a mixture database 801, a local factors database802, a components database 803, and a tolerances database 804. A mixtureformulation 810 associated with a particular mixture is maintained inmixture database 801. While only one mixture formulation is shown inFIG. 8, it is to be understood that more than one mixture formulation(each associated with a respective mixture) may be stored by masterdatabase module 11.

Master database module 11 is linked to several production facilities, asshown in FIG. 8. In the illustrative embodiment, master database module11 is in communication with Production Facility A (841), located inLocality A, Production Facility B (842) located in Locality B, andProduction Facility C (843), located in Locality C. While threeproduction facilities (and three localities) are shown in FIG. 8, inother embodiments more or fewer than three production facilities (andmore or fewer than three localities) may be used.

In the embodiment of FIG. 8, local factors database 802 stores localfactor data relating to various production facilities, including, forexample, local availability information, local cost information, localmarket condition information, etc. Localization module 19 may obtainlocal factor data based on the information in local factors database802. Components database stores information pertaining to variouscomponents of product mixtures, such as, for example, technicalinformation concerning various components, costs of various components,etc. Tolerances database 804 stores information defining tolerancesrelated to various components and mixtures.

In the illustrative embodiment, localization module 19 accesses mixtureformulation 810 and generates a localized version for ProductionFacility A (841), shown in FIG. 8 as Mixture Formulation A (810-A).Localization module 19 generates a localized version for ProductionFacility B (842), shown in FIG. 8 as Mixture Formulation B (810-B).Localization module 19 also generates a localized version for ProductionFacility C (843), shown in FIG. 8 as Mixture Formulation C (810-C).Mixture Formulation A (810-A), Mixture Formulation B (810-B), andMixture Formulation C (810-C) are stored at master database module 11.

In order to generate a localized version of a mixture formulation for aparticular production facility, localization module 19 accesses localfactors database 802 and analyzes one or more local factors pertainingto the particular production facility. For example, localization module19 may analyze one or more local availability factors representing localavailability of components in the mixture formulation, one or more localmarket condition factors representing characteristics of the localmarket, one or more local cost factors representing the cost ofobtaining various components in the local market, etc.

Localization module 19 may modify a mixture formulation based on a localfactor. For example, if a local market factor indicates a strongpreference for a product having a particular feature (or a strong biasagainst a certain feature), localization module 19 may alter the mixtureformulation based on such local market conditions. If a particularcomponent is not available in a local market, localization module 19 mayalter the mixture formulation by substituting an equivalent componentthat is locally available. Similarly, if a particular component isprohibitively expensive in a particular locality, localization module 19may reduce the amount of such component in the mixture formulationand/or replace the component with a substitute, equivalent component.

It is to be understood that FIG. 8 is illustrative. In otherembodiments, master database module 11 may include components differentfrom those shown in FIG. 8. Mixtures and local factors may be stored ina different manner than that shown in FIG. 8.

FIG. 9 is a flowchart of a method of generating localized versions of amixture formulation in accordance with an embodiment. The methodpresented in FIG. 9 is discussed with reference to FIG. 10. FIG. 10shows mixture formulation 810 and several corresponding localizedversions of the mixture formulation in accordance with an embodiment.

At step 910, a formulation of a product is stored, the formulationspecifying a plurality of components and respective quantities. Asdiscussed above, mixture formulation 810 is stored at master databasemodule 11. Referring to FIG. 10, mixture formulation 810 specifies thefollowing components and quantities: C-1, Q-1; C-2, Q-2; C-3, Q-3; C-4,Q-4; and C-5, Q-5. Thus, for example, mixture formulation 810 requiresquantity Q-1 of component C-1, quantity Q-2 of component C-2, etc.Mixture formulation 810 may also specify other information, including amethod to be used to manufacture the mixture.

At step 920, a plurality of production facilities capable of producingthe product are identified, each production facility being associatedwith a respective locality. In the illustrative embodiment, localizationmodule 19 identifies Production Facility A (841) in Locality A,Production Facility B (842) in Locality B, and Production Facility C(843) in Locality C.

Referring to block 930, for each respective one of the identifiedproduction facilities, a series of steps is performed. At step 940, alocal factor that is specific to the corresponding locality and thatrelates to a particular one of the plurality of components isidentified. Localization module 19 first accesses local factors database802 and examines local factors relating to Locality A and ProductionFacility A (841). Suppose, for example, that localization module 19determines that in Locality A, component C-1 is not readily available.

At step 950, the formulation is modified, based on the local factor, togenerate a localized version of the formulation for use at therespective production facility. In the illustrative embodiment of FIG.10, localization module 19 substitutes an equivalent component SUB-1 forcomponent C-1 to generate a localized version 810-A of mixture 810.Localized version 810-A is intended for use at Production Facility A(841).

At step 960, the localized version of the formulation is stored inassociation with the formulation. In the illustrative embodiment,localized version 810-A is stored at master database module 11 inassociation with mixture formulation 810.

Referring to FIG. 9, the routine may return to step 930 and repeat steps930, 940, 950, and 960 for another production facility, as necessary.Suppose, for example that localization module 19 determines that inLocality B (associated with Production Facility B (842)), localpurchasers prefer a product with less of component C-2. Localizationmodule 19 thus reduces the quantity of component C-2 in the respectivelocalized version 810-B of mixture 810, as shown in FIG. 10. Inparticular, the amount of component C-2 in localized version 810-B is(0.5)*(Q-2). Localized version 810-B is intended for use at ProductionFacility B (842). Localized version 810-B is stored at master databasemodule 11 in association with mixture formulation 810, as shown in FIG.8.

Suppose that localization module 19 also determines that in Locality C(associated with Production Facility C (843)), local purchasers prefer aproduct with an additional component C-6. Localization module 19 furtherdetermines that component C-6 is an equivalent of component C-5, but isof lower quality. To accommodate local market conditions, localizationmodule 19 reduces the quantity of component C-5 to (0.7)*(C-5) and alsoadds a quantity Q-6 of component C-6 to generate a localized version810-C of mixture 810, as shown in FIG. 10. Localized version 810-C isintended for use at Production Facility C (843). Localized version 810-Cis stored at master database module 11 in association with mixtureformulation 810, as shown in FIG. 8.

Master database module 11 may subsequently transmit one or more of thelocalized versions 810-A, 810-B, 810-C to Production Facilities A, B,and/or C, as necessary. For example, suppose that an order is receivedfor Mixture Formulation 810. Suppose further that Production Facility Aand Production Facility B are selected to produce the mixture. Masterdatabase module 11 accordingly transmits the localized version MixtureFormulation A (810-A) to Production Facility A (841). MixtureFormulation A (810-A) is stored at Production Module 14. Master databasemodule 11 also transmits the localized version Mixture Formulation B(810-B) to Production Facility B (842). Mixture Formulation B (810-B) isstored at a respective production module (not shown) operating atProduction Facility B (842).

The mixture is then produced at each designated production facilitybased on the respective localized version of the mixture formulation. Inthe illustrative embodiment, the mixture is produced at ProductionFacility A (841) in accordance with the localized version MixtureFormulation A (810-A)). The mixture is produced at Production Facility B(842) in accordance with the localized version Mixture Formulation B(810-B).

In accordance with another embodiment, master database module 11 fromtime to time updates the master version of a mixture formulation (storedat master database module 11). Master database module 11 also monitorsversions of the mixture formulation maintained at various productionfacilities. If it is determined that a version of the mixtureformulation stored at a particular production facility is not the sameas the master version of the mixture formulation, an alert is issued andthe local version is synchronized with the master version. For purposesof the discussion set forth below, any version of a mixture formulationthat is stored at master database module 11 may be considered a “masterversion” of the mixture formulation.

In an illustrative embodiment, suppose that master database module 11updates Mixture Formulation 810. This may occur for any of a variety ofreasons. For example, the cost of one of the components in MixtureFormulation 810 may increase substantially, and the particular componentmay be replaced by an equivalent component. Referring to FIG. 11A, theupdated formulation is stored at master database module 11 as UpdatedMixture Formulation 810U.

Master database module 11 also generates localized versions of theupdated mixture formulation. Thus, for example, master database module11 generates an updated localized version of Mixture Formulation 810Ufor Production Facility 841 (in Locality A). The updated localizedversion of is stored at master database module 11 as Updated MixtureFormulation A (810U-A), as shown in FIG. 11A.

Master database module 11 identifies one or more production facilitiesthat store a localized version of Mixture Formulation 810, and notifieseach such production module that Mixture Formulation 810 has beenupdated. If a production module does not have the correct updatedversion of the mixture formulation, the localized version must besynchronized with the updated master version stored at master databasemodule 11. FIG. 12 is a flowchart of a method of synchronizing alocalized version of a mixture formulation with a master version of themixture formulation in accordance with an embodiment.

In the illustrative embodiment, certain aspects of production atProduction Facility A (841) are managed by production module 14. Forexample, production module 14 may operate on a computer or otherprocessing device located on the premises of Production Facility A(841). At step 1210, a determination is made that a mixture formulationstored at a particular production facility is different from the mixtureformulation stored by the master database module. For example, masterdatabase module may communicate to production module 14 (operating atProduction Facility A (841)) that Mixture Formulation A (810-A) has beenupdated. Production module 14 determines that its current localizedversion of the mixture formulation is not the same as Updated MixtureFormulation A (810U-A).

At step 1220, an alert is transmitted indicating that the version of themixture formulation stored at the particular production facility isdifferent from the mixture formulation stored by master database module11. Accordingly, production module 14 transmits an alert to masterdatabase module 11 indicating that its local version of the mixtureformulation is not the same as the updated version stored at masterdatabase module 11.

At step 1230, the version of the mixture formulation stored at theparticular production facility is synchronized with the mixtureformulation stored at the master database module 11. In response to thealert, master database module 11 provides production module 14 with acopy of Updated Mixture Formulation A (810U-A). Production module 14stores Updated Mixture Formulation A (810U-A), as shown in FIG. 11B.

Various methods and system described above may be used in an integratedclosed-loop production system to manage a production system. Inaccordance with an embodiment, a method of managing a closed-loopproduction system is provided. Master database module 11 provides tosales module 13 descriptions, prices, and other information relating toa plurality of available mixtures, enabling sales module 13 to offerseveral options to potential customers. Specifically, master databasemodule 11 provides information relating to a plurality of concretemixtures. Sales module 13 may present the information to a customer inthe form of a menu, as discussed above with reference to FIG. 1B.

Suppose now that a customer considers the available mixtures and selectsone of the plurality of concrete mixtures. Suppose further that thecustomer submits an order for the selected mixture, specifyingparameters such as quantity, date and place of delivery, etc. Forillustrative purposes, suppose that the customer selects the mixtureassociated with mixture formulation 810 (shown in FIG. 8) and specifiesa delivery site located in or near Locality A (also shown in FIG. 8).Master database module 11 utilizes a closed-loop production system suchas that illustrated in FIG. 1A to manage the sale, production anddelivery of the selected mixture to the customer.

FIGS. 13A-13B comprise a flowchart of a method of managing a closed-loopproduction system in accordance with an embodiment. At step 1310, anorder for a mixture selected from among the plurality of mixtures isreceived, by a processor, from a sales module operating on a firstdevice different from the processor, the order being associated with apurchase of the mixture by a customer. In the illustrative embodiment,sales module 13 transmits the order for the selected concrete mixture tomaster database module 11. The order specifies the selected mixture andother information including quantity, date and place of delivery, etc.Master database module 11 receives the order for the selected concretemixture from sales module 13.

At step 1310, a mixture formulation defining a plurality of componentsand respective quantities required to produce the selected mixture isprovided, by the processor, to a production module operating on a seconddevice located at a production facility capable of producing themixture. Accordingly, master database module 11 identifies one or moreproduction facilities capable of producing the selected mixture.Production facilities may be selected based on a variety of factors. Forexample, master database module 11 may select one or more productionfacilities that are located near the delivery site specified in theorder. In the illustrative embodiment, master database module 11 selectsProduction Facility A (841) due to the fact that the customer's deliverysite is located in or near Locality A. It is to be understood that morethan one production facility may be selected and used to produce amixture to meet a particular order.

Master database module 11 transmits Mixture Formulation A (810-A) (orany updated version thereof) to Production Facility A (841). Productionmodule 14 manages and monitors the production process. In theillustrative embodiment, production module 14 determines that aparticular component of mixture formulation A (810-A) is currentlyunavailable and replaces the component with a known equivalent.Production module 14 accordingly transmits an alert to master databasemodule 11 indicating that the component has been replaced. An alert maythen be provided to the customer, as well. Production of the selectedmixture proceeds. In one embodiment, the alert may be transmitted inreal time (e.g., within a specified time period after production module14 receives the information).

At step 1315, first information identifying a modification made to themixture formulation is received, by the processor, from the productionmodule, prior to production of the mixture. Master database module 11receives the alert from production module 14.

At step 1320, an alert is transmitted if the first information does notmeet a first predetermined criterion. If the modification does not meetspecified requirements, master database module 11 transmits an alert tothe customer. In one embodiment, the alert is transmitted in real time.

In the illustrative embodiment, a quantity of the mixture actuallyproduced at Production Facility A (841) differs from the quantityspecified in the order. Production module 14 transmits an alert tomaster database module 11 and to alert module 17 indicating that thequantity actually produced differs from the quantity ordered. The alertmay be transmitted in real time. At step 1325, second informationindicating an actual quantity of the mixture produced is received, fromthe production module, prior to delivery of the mixture. Master databasemodule 11 receives the alert and stores the information specifying theactual quantity produced.

At step 1330, an alert is transmitted if the second information does notmeet a second predetermined criterion. If the quantity of concretemixture actually produced does not meet specified requirements, masterdatabase module 11 transmits an alert to the customer. In oneembodiment, the alert is transmitted in real time.

In another embodiment, production module 14 may inform master databasemodule 11 if the method of manufacture specified in the mixtureformulation is changed. For example, a step of the method may bemodified or eliminated, or a new step may be added.

The method now proceeds to step 1335 of FIG. 13B.

The mixture is now placed on a transport vehicle, such as a truck, andtransported to the delivery site specified in the order. The vehicleincludes transport module 15, which may be a software applicationoperating on a processing device, for example. The vehicle may have oneor more sensors to obtain data such as temperature of the mixture, watercontent of the mixture, etc. During transport, transport module 15monitors the condition of the mixture and detects changes made to themixture.

At step 1335, third information identifying a change made to the mixtureproduced during transport of the mixture is received, from a transportmodule operating on a third device located on a vehicle transporting themixture produced from the production facility to a delivery site. In theillustrative embodiment, the driver of the truck makes a change to themixture during transport to the delivery site. For example, the drivermay add additional water to the mixture while the mixture is in thetruck. Transport module 15 transmits an alert to master database module11 and to alert module 17 indicating the change that was made. In oneembodiment, the alert is transmitted in real time.

At step 1340, an alert is transmitted if the third information does notmeet a third predetermined criterion. If the third information is notwithin pre-established tolerances, an alert is issued to the customer.In one embodiment, the alert is transmitted in real time.

In the illustrative embodiment, the mixture is delivered to thecustomer's construction site. At the customer's site, site module 16monitors delivery of the mixture and performance of the mixture afterdelivery. At step 1345, fourth information relating to delivery of themixture produced is received, from a site module operating on a fourthdevice associated with the delivery site. When the mixture is deliveredto the specified delivery site, site module 16 transmits an alert tomaster database module indicating that the mixture has been delivered.In one embodiment, the alert is transmitted in real time.

At step 1350, an alert is transmitted if it is determined that thefourth information does not meet a fourth predetermined criterion. Forexample, if the delivery of the mixture occurs outside of a specifieddelivery time frame (e.g., if the delivery is late), master databasemodule 11 (or alert module 17) may transmit an alert to the customer. Inone embodiment, the alert is transmitted in real time.

The site module 16 may also monitor certain performance parameters ofthe mixture after it is delivered and used. At step 1355, fifthinformation relating to a performance of the mixture is received, fromthe site module. After the mixture is used (e.g., when the concretemixture is laid), site module 16 may transmit to master database module11 information including performance data. In one embodiment, theinformation is transmitted in real time.

At step 1360, an alert is transmitted if it is determined that the fifthinformation does not meet a fifth predetermined criterion. Thus, if theperformance data does not meet specified requirements, master databasemodule 11 (or alert module 17) transmits an alert to the customer. Inone embodiment, the alert is transmitted in real time.

As described above, alerts are issued at various stages of theproduction process to inform master database module 11 of events andproblems that occur during production, transport, and delivery of themixture. Master database module 11 (or alert module 17) may then alertthe customer if a parameter does not meet specified requirements.

Master database module 11 may collect information from various modulesinvolved in the production of a mixture, in real time, and provide theinformation to the customer, in real time. For example, when masterdatabase module 11 receives from a respective module informationpertaining to the production of a mixture, master database module 11 maytransmit an alert to the customer in the form of an email, or in anotherformat.

In one embodiment, master database module 11 maintains a web pageassociated with a customer's order and allows the producer (and/or thecustomer) to access the web page. Information received from variousmodules involved in the production of the mixture may be presented onthe web page. In addition, information relating to cost analysis may bepresented on the web page. For example, an analysis of the impact of amodification to the mixture formulation, a change to the mixture duringproduction or transport, a delay in delivery, or any other event, on thecost of materials (COM) and/or on the producer's profitability may beprovided on the web page.

FIG. 14 shows an exemplary web page that may be maintained in accordancewith an embodiment. For example, access to the web page may be providedto a producer to enable the producer to manage the production system andto control costs and profitability. Web page 1400 includes a customer IDfield 1411 showing the customer's name or other identifier, a mixturepurchased field 1412 showing the mixture that the customer purchased, aquantity field 1413 showing the quantity of the mixture ordered, and adelivery location field 1414 showing the delivery location specified bythe customer.

Web page 1400 also includes a Production-Related Events field 1420 thatlists events that occur during production of the mixture. Masterdatabase module 11 may display in field 1420 information received fromvarious modules during production of the mixture, including informationindicating modifications made to the mixture formulation prior toproduction, changes made to the mixture during transport of the mixture,information related to delivery, etc. In the illustrative embodiment ofFIG. 14, field 1420 includes a first listing 1421 indicating thatcomponent C-5 of the mixture formulation was replaced by an equivalentcomponent EQU-1 at Production Facility A (prior to production). Field1420 also includes a second listing 1422 indicating that delivery of themixture was completed on 04-19-XXXX.

Web page 1400 also includes a Cost Impact Table 1431 showing theexpected impact of certain events on cost and profitability. Table 1431includes an event column 1441, a cost impact column 1442, and aprofitability impact column 1443. Master database module 11 accessesstored information concerning the costs of various components andcalculates the expected impact of one or more selected events on theproducer's costs. In the illustrative embodiment, row 1451 indicatesthat the replacement of C-5 by EQU-1 is expected to increase the cost ofthe mixture by +2.1%, and reduces the producer's profit by 6.5%.

In accordance with another embodiment, statistical measures of variousaspects of the production process are generated for a plurality ofproduction facilities and used to establish one or more benchmarks.

Concrete performance is generally specified and used on the basis of its28 day compressive strength, or at times for pavement construction onthe basis of its flexure strength at a specified age such as 7 or 28days. The methods of measurement and reporting are generally specifiedby the American Society for Testing and Materials, or ASTM (such as ASTMC39 and C78) and the equivalent International standards such asapplicable EN (European Norms). Additionally, concrete mix design andquality evaluation is guided by American Concrete Institute (ACI) 318 asa recommended procedure, which is almost always mandated by projectspecifications in the US, and also used in many countries worldwide. InACI 318 a set of statistical criteria are established that relateconcrete mix design strength, F′cr, to its structural grade strength,F′c, as used in the design process by the structural engineer. Thus theconcrete producer designs his or her mixtures to meet certain F′crvalues in order to meet certain desired F′c structural grades specifiedin the project specifications. A variable relating F′cr and F′c is thestandard deviation of strength testing, SDT, as determined perprescribed ACI procedures. The ACI formulae include:

For F′c≦5,000 psi:

F′cr=F′c+1.34 SDT  (ACI 1)

(1% probability that the run average of 3 consecutive tests are belowF′c)

F′cr=F′c−500+2.33 SDT  (ACI 2)

(1% probability that a single test is 500 psi or more below F′c)

For F′c>5,000 psi—[1] applies but[2] is replaced by [3] below:

F′cr=F′c−0.1F′c+2.33 SDT  (ACI 3)

(1% probability that a single test is 10% of F′c or more below F′c)

In general the above equations can be expressed in the following form:

Mix Design Strength (F′cr)=Structural Grade Strength (F′c)+An overdesignfactor proportional to the Standard Deviation of testing, SDT.

The factor SDT is a direct measure of concrete quality and reliability,and experience shows that it can range widely from an excellent level ofon the order of 80 to 200 psi, to the very poor level of over 1,000 psi.Concrete mix design cost factor is directly proportional to SDT, whichmeans that high quality concrete is also less expensive to produce sinceit would contain less cement (or cementitious materials, which includebinders such as slag, fly ash, or silica fume in addition to cement).

Because of the above ACI approach now in practice for many decades, theindustry (including ready mix producers, test labs, contractor, andspecifying engineers) has paid significant attention to test resultsvariability and the standard deviation of testing.

FIG. 15 shows a production management system 1500 in accordance with anembodiment. Product management system 1500 includes a master databasemodule 11, input module 12, sales module 13, production module 14,transport module 15, site module 16, alert module 17, purchase module18, and localization module 19. Production management system 1500 alsoincludes a comparison module 1520, a network 1575 and a cloud database1530. Various components, such as master database module 11, may fromtime to time store data in cloud database 1530. Production managementsystem 1500 also comprises a user device 1540.

In another embodiment, the master database module 11, the comparisonmodule 1520, and the alert module 17 are housed within a single module.

In one embodiment, a batch of a concrete mixture is produced at aproduction facility in accordance with a formulation. Certain aspects ofthe batch produced are measured and differences between the batchproduced and the formulation requirements are identified. Thedifferences are analyzed to determine if the differences fall withinacceptable tolerances.

FIGS. 16A-16B comprise a flowchart of a method of producing andanalyzing a mixture in accordance with an embodiment. At step 1605, amixture formulation is input into a master database module. In theillustrative embodiment, input module 12 provides a formulation for aparticular concrete mixture to master database module 11. Masterdatabase module 11 stores the formulation.

In one embodiment, a plurality of mixture formulations is provided byinput module 12 to master database module 11. A master list of mixtures,comprising a plurality of mixture formulations, is maintained at masterdatabase module 11.

As described above, master database module 11 may generate localizedversions of a mixture formulation. Referring again to FIG. 8,localization module 19 generates localized mixture formulations forProduction Facility A, Production Facility B, etc.

At step 1610, data relating component types and costs are input into themaster database module. Technical data for a variety of components usedin the formulation (and in other formulations), as well as cost data forthe components, is provided by input module 12 to master database module11. Technical data and cost data for various components may be stored ina components database 803, shown in FIG. 8.

At step 1615, first tolerance data and second tolerance data are inputinto the master database module. Input module 12 transmits to masterdatabase module 11 information defining a first tolerance andinformation defining the second tolerance. For example, tolerances mayindicate that an amount of water in a batch of a concrete mixture mustfall within a specified range, or that an amount of cementitious in theconcrete mixture must fall within a specified range. Toleranceinformation is stored in tolerances database 804.

At step 1620, a formulation is provided to the production module. Masterdatabase module 11 transmits the mixture formulation to a selectedproduction facility. For example, master database module 11 may providea respective localized mixture formulation to Production Facility A(841). A different localized mixture formulation may be provided toProduction Facility B (842), for example.

At step 1625, the mixture is produced at the production facility. Theproduction facility produces one or more batches of the mixture. Forexample, Production Facility A (841) may produce a batch of the mixturebased on the mixture formulation.

At step 1630, actual mixture data is provided to master database module.After a batch is made, production module 14 provides batch dataindicating the actual quantity of the mixture produced, the componentsused to make the batch, the quantity of each component, etc., to masterdatabase module 11. Production module 14 obtains batch data indicatingthe actual quantity of the mixture produced, which components wereactually used, etc., and transmits the batch data to master databasemodule 11. Master database module 11 may store the batch data. Themethod now proceeds to step 1635 of FIG. 16B.

At step 1635, the comparison module compares the actual mixture data tothe first tolerance. Comparison module 1520 accesses the stored batchdata, and accesses tolerance information in tolerances database 804(shown in FIG. 8). Comparison module 1520 applies the first tolerance tothe batch data to determine whether the batch data is acceptable.

At step 1640, the comparison module compares the actual mixture data tothe second tolerance. Comparison module 1520 accesses the stored batchdata and applies the second tolerance to the batch data to determinewhether the batch data is acceptable.

Referring to block 1645, a determination is made whether the actualmixture data are within the first tolerance and the second tolerance.Comparison module 1520 determines whether the actual mixture data arewithin the specified tolerances. If the actual mixture data are withinthe first tolerance and the second tolerance, the method proceeds tostep 1660. If the actual mixture data are not within the first toleranceand the second tolerance, the method proceeds to step 1650.

At step 1650, an alert is transmitted to the master database module.Comparison module 1520 transmits to master database module 11 an alertindicating that the batch data are not within acceptable tolerances.

At step 1655, an alert is transmitted to the customer. Alert module 17transmits to the customer an alert indicating that the batch data arenot within acceptable tolerances.

In another embodiment, a first alert is issued if the batch data is notwithin the first tolerance, and a second alert is issued if the batchdata is not within the second tolerance.

At step 1660, the mixture is delivered to the customer site. The mixtureis placed on a transport vehicle and is delivered to the site specifiedby the customer in the order.

In accordance with another embodiment, comparison module 1520 monitorsthe quantity of one or more components in each batch actually produced,and compares the amounts to the amounts of such components as specifiedin the formulation.

FIG. 17 is a flowchart of a method of producing a formulation-basedmixture in accordance with an embodiment. In another illustrativeembodiment, suppose that another customer orders a desired quantity ofthe mixture defined by Mixture Formulation (810). Several productionfacilities may be selected to produce the mixture, including ProductionFacility C (841). Master database module 11 transmits localized MixtureFormulation C (810-C) to production facility C (843).

At step 1710, a batch of a mixture is produced based on a formulation. Abatch of the mixture is produced at Production Facility C (843) based onlocalized Mixture Formulation A (810-C). Referring to FIG. 10, localizedMixture Formulation (810-C) specifies the following components andquantities: C-1, Q-1; C-2, Q-2; C-3, Q-3; C-4, Q-4; C-5, (0.7)*(Q-5);and C-6, Q-6.

Referring to block 1720, for each component X in the batch, a series ofstep is performed. Thus, the steps described below are performed withrespect to each of the components C-1, C-2, C-3, C-4, C-5, and C-6. Forconvenience, the method steps are described with respect to componentC-1; however, the steps are also performed for each of the othercomponents.

At step 1730, the actual quantity of the component in the batchedmixture, XB, is determined. Thus, the actual quantity of C-1 used in thebatch produced at Production Facility C (843) is determined. Productionmodule 14 obtains this information concerning the actual quantity of thecomponent in the batched mixture, XB, and transmits the information tomaster database module 11.

Now a measure of a difference between the batch and the formulation isdetermined based on a relationship between the quantity of the componentin the batched mixture, XB, and the quantity of the component asspecified by the formulation, XF.

Specifically, at step 1740, a difference between the quantity of thecomponent specified in the formulation and the actual quantity of thecomponent in the batch produced is calculated. Specifically, thedifference (XB−XF) is calculated, where XB is the amount of thecomponent actually used in the batch produced and XF is the amount ofthe component as specified in the formulation. A percentage valuerepresenting the difference may then be computed using the followingformula:

ΔX=(XB−XF)/XF.

In the illustrative embodiment, comparison module 1520 calculates thequantity ΔX, and provides the information to master database module 11.The quantity ΔX is stored at master database module 11.

At step 1750, a difference between the cost of the component asspecified in the formulation and the cost of the component in the batchproduced is calculated. Thus, the difference ($XB−$XF) is calculated,where $XB is the cost of the component actually used in the batchproduced and $XF is the cost of the component as specified in theformulation. A percentage value representing the difference is thencalculated using the following formula:

Δ$X=($XB−$XF)/$XF,

In the illustrative embodiment, comparison module 1520 calculates thequantity Δ$X and provides the information to master database module 11.The quantity Δ$X is stored at master database module 11.

In accordance with an embodiment, comparison module 1520 particularlymonitors the quantity of cementitious and the quantity water in eachbatch. Systems and methods for monitoring and analyzing quantities ofcementitious and water in batches produced are described below.

For convenience, the terms CMF, CMB, WF, and WB are defined as follows:

CM_(F)=the amount of cementitious specified in the formulation,

CM_(B)=the actual amount of cementitious in a batch produced,

W_(F)=the amount of water specified in the formulation,

W_(B)=the actual amount of water in a batch produced.

Then ΔCM and ΔW are defined as follows:

ΔCM=CM_(B)−CM_(F)

ΔW=W_(B)−W_(F)

Using the terms defined above, set forth below is a method of computinga standard deviation of ΔCM/CM_(F) (referred to as SDrCM) and a standarddeviation of ΔW/W_(F) (referred to as SDrW, for each productionfacility, across all its production batches and mixes.

In accordance with well-known principles of concrete technology, andsince strength is proportional to CM/W ratio, it can be shown that forany given mix, a variance of the strength S of a given batch of concretehas the following relationship to CM and W:

ΔS/S=(ΔCM/CM)−(ΔW/W)

Accordingly, relative strength increases as CM specified in theformulation increases. Likewise, relative strength increases as Wspecified in the formulation decreases.

In accordance with well-known statistical principles, the variance (VAR)of the strength measure can be expressed as follows:

VAR(Δ S/S) = VAR( Δ CM/CM) + VAR(Δ W/W) = (SDrCM)² + (SDrW)²

Now if SDrWCM is the standard deviation of the measured ratio W/CM in abatch actually produced relative to the value of W/CM specified in theformulation, the SDrWCM can be expressed as follows:

(SDrWCM)=[(SDrCM)²+(SDrW)]^(1/2)

Hence:

SDrS=(SDrWCM),

where SDrS is the standard deviation of relative strength resulting fromthe variability of the batching process. The term “relative strength” asused herein means the difference in strength in all batches actuallyproduced at a given production facility relative to the strengthbaseline specified in the formulation, due to the batching variabilitiesof CM and W, expressed as a ratio with respect to the strength baselinespecified in the formulation.

It follows that:

SD(ΔS)=S×(SDrWCM)

In accordance with an embodiment, the closed loop production managementsystem described herein provides, in real time, to a producer and/or acustomer, the statistical values SDrCM and SDrW, and SD(ΔS). SD(ΔS) is adirect measure of concrete strength performance quality related to thequality of the production batching process, both of which arecharacterized by the applicable SD values. Low batching quality isreflected by a high SD value; high batching quality is reflected by alow SD. Thus as the batching quality deteriorates, the strength qualityalso decreases proportionally.

Accordingly, when the batching quality decreases, it may be necessary toadjust the applicable formulation by using an extra batching drivenincrement in the SDT standard deviation factor. This is done using theACI 318 Eqs.[1]-[3] and the equation above in the following form:

ΔF′cr=1.34×S×(SDrWCM)  [1a]

ΔF′cr=2.33×S×(SDrWCM)  [2a]

ΔF′cr=2.33×S×(SDrWCM)  [3a]

where ΔF′cr is an added mix design strength increment resulting from thebatching variability SDrWCM, for each of the three ACI equations. SinceEquations [2a] and [3a] are identical, the three ACI statisticalcriteria are in fact reduced to two for these batching increment cases.

Because F′cr is the theoretical strength associated with the specifiedformulation, an increase in F′cr is associated with an increase in theCM content at constant W, resulting in an increase in the cost of the CMcost in the mixture. The cost of CM in a mixture can be expressed asfollows:

Φ=CM efficiency factor in PSI/(LB·CYD)

K=CM cost per LB

$CM=CM cost per cyd=(K/Φ)×F′cr

It follows from the equation above and Equations [1a-1b] that:

Δ$CMB=increase in CM cost due to batching SD

Δ$CMB=1.34×(K/Φ)×S×SDrWCM

ΔCSTB=2.33×(K/Φ)×S×SDrWCM

Accordingly, in accordance with an embodiment, standard deviations aredetermined in according with the principles described above, and areused to determine a measure of concrete strength performance quality fora plurality of batches produced at a production facility. FIG. 18 is aflowchart of a method of determining a measure of concrete strengthperformance quality for concrete produced at a production facility inaccordance with an embodiment.

At step 1810, a first difference between a measured quantity ofcementitious and a first quantity specified in a formulation isdetermined, for each of a plurality of batches of concrete produced at aproduction facility. As described above, for each batch, the batched CMis measured, and information indicating the batched CM is provided tomaster database module 11. Comparison module 1520 then determines thedifference ΔCM between the batched CM and the CM amount specified in theformulation.

At step 1820, a first standard deviation is determined based on thefirst differences. In the illustrative embodiment, comparison module1520 calculates the Standard Deviation SDrCM of the difference ofbatched CM versus design specification (formulation) CM over all batchesproduced in the production facility.

At step 1830, a second difference between a measured quantity of waterand a second quantity specified in the formulation is determined foreach of the plurality of batches. As described above, for each batch,the batched W is measured, and information indicating the batched W isprovided to master database module 11. Comparison module 1520 determinesthe difference ΔW between the batched W and the W amount in theformulation.

At step 1840, a second standard deviation is determined based on thesecond differences. Comparison module 1520 calculates the StandardDeviation SDrW of the difference of batched W versus the designspecification (formulation) W over all batches produced in theproduction facility.

At step 1850, a measure of concrete strength performance quality isdetermined for the production facility based on the first standarddeviation and the second standard deviation. In the manner describedabove, comparison module 1520 determines SD(ΔS) based on SDrCM and SDrW.

At step 1860, a measure of a cost of adjusting the formulation isdetermined based on the measure of concrete strength performancequality. Comparison module 1520 calculates the potential impact on costsof adjusting the design specification (formulation). For example, asdescribed above, increasing F′cr may result in an increase in costs dueto an increase in the cost of CM in the mixture. The increase in CM costΔ$CMB may be calculated using equations discussed above.

In accordance with another embodiment, statistical data is provided to aproducer and/or a customer, for example, via a web page displayed on auser device. Suppose, for example, that a producer who owns and/ormanages a plurality of production facilities wishes to compare theperformance of the various production facilities. Statisticalperformance measures of the respective performance facilities areprovided. For example, in the illustrative embodiment of FIG. 15, theproducer may employ user device 1540 to access a web page and view thestatistical data.

FIGS. 19A-19B comprise a flowchart of a method of providing comparativestatistical information relating to a plurality of production facilitiesin accordance with an embodiment. Referring to block 1910, for each of aplurality of production facilities, a series of actions is performed asdescribed below.

For a selected production facility (such as Production Facility A(841)),the following steps are performed. At step 1920, a first standarddeviation of a first difference between a measured quantity ofcementitious and a first quantity specified in a design specification isdetermined. Comparison module 1520 computes the first standard deviationSDrCM of the difference of batched CM versus design specification(formulation) CM over all batches produced in the production facility,as described above in steps 1810-1820.

At step 1930, a second standard deviation of a second difference betweena measured quantity of water and a second quantity specified in thedesign specification is determined. Comparison module 1520 computes thesecond standard deviation SDrW of the difference of batched W versus thedesign specification (formulation) W over all batches produced in theproduction facility, as described above in steps 1830-1840.

At step 1940, a measure of concrete strength performance quality for theproduction facility is determined based on the first standard deviationand the second standard deviation. Comparison module 1520 computesSD(ΔS) based on SDrCM and SDrW, as described above in step 1850.

Referring to block 1950, the method may return to step 1920 andstatistics for another production facility may be generated in a similarmanner. Preferably, statistical information is generated for a pluralityof production facilities. Otherwise, the method proceeds to step 1960 ofFIG. 19B.

At step 1960, information indicating each of the plurality of productionfacilities and, for each respective production facility, thecorresponding first standard deviation, the corresponding secondstandard deviation, and the corresponding measure of concrete strengthperformance quality, is provided in a display. In one embodiment, thestatistical information computed by comparison module 1520 may bedisplayed on a web page such as that shown in FIG. 20. Web page 2001includes a statistics table 2010 which includes six columns 2011, 2012,2013, 2014, 2015, and 2016. Production facility identifier column 2011includes identifiers for a plurality of production facilities. Columns2012, 2013, 2014, and 2015 store values for SDrCM, SDrW, SDrWCM, andSD(ΔS), respectively, for each respective production facility listed.For example, referring to record 2021, the production facilityidentified as PF-1 has the following statistics: sdrcm-1; sdrw-1;sdrwcm-1; sd-1. Column 2016 displays a potential cost savings for eachproduction facility listed.

At step 1970, a first benchmark is selected from among a first pluralityof first standard deviations. For example, in the illustrativeembodiment, comparison module 1520 may determine that the standarddeviation associated with the best performance among those displayed inSDrCM column 2012 is sdrcm-2 (shown in record 2022).

At step 1980, a second benchmark is selected from among a secondplurality of second standard deviations. For example, comparison module1520 may determine that the standard deviation associated with the bestperformance among those displayed in SDrW column 2013 is sdrw-4 (shownin record 2024).

At step 1990, the first benchmark and the second benchmark are indicatedin the display. In the illustrative embodiment, the benchmark standarddeviations are displayed, respectively, in a Benchmark (SDrCM) field2031 and a Benchmark (SDrW) field 2032. The two benchmark values arealso highlighted in columns 2012, 2013. In other embodiments, thebenchmark values may be indicated in a different manner. In anotherembodiment, a benchmark standard deviation of strength (PSI) isdetermined based on the benchmark values from fields 2031, 2032, and/orvalues in column 2014. Benchmark consistency values may also bedetermined. The benchmark standard deviation of strength and thebenchmark consistency values may also be displayed on page 2001.

At step 1995, a potential cost savings value representing an amount thatmay be saved by improving production at the production facility to thebenchmark is displayed in the display. For example, comparison module1520 determines, for each production facility listed, how much savingsmay be achieved by improving the production process at the facility tomeet the first and second benchmarks. In the illustrative embodiment ofFIG. 20, the cost savings information is displayed in column 2016.

In another embodiment, a single generalized benchmark is determinedbased on the first benchmark and the second benchmark. A potential costsavings value is determined based on the generalized benchmark.

These and other aspects of the present Invention may be more fullyunderstood by the following Examples.

Example Illustration of the Impact of Concrete SD on its CM Cost

As shown in Table 1, concrete variability impacts its CM (cementitiouscost) cost very significantly. The analysis is performed for a concreteof structural grade 4,000 psi, and using the referenced equationspreviously derived in this document. The example analysis assumes a CMefficiency factor, Φ=8 psi/(LB·cyd), and a CM cost, K=$0.045/Lb.Starting at a SD of 200 psi, the SD is increased in 100 psi incrementsin column 2, the mix design strength computed in columns 3 & 4 per twodifferent ACI formulae, with the higher value always governing. The mixCM cost is computed in column 5. The cost of quality variability is wellillustrated in columns 6 & 7; column 6 shows that per each 100 psiincrease in standard deviation of strength, the CM cost will increasebetween $0.75 to $1.31 per cyd. Column 7 shows that the CM cost relativeto very high quality concrete (represented by row 1) can increasedramatically by more than $8/cyd. Noting that the concrete industry onaverage generates a net profit of on the order of $0.5 to $2 per cyd,this example (using realistic numbers) illustrates the tremendousimportance of maintaining low variability.

An important factor for maintaining low strength performance variabilityis the consistency of the batching process.

TABLE 1 Ref# 1 2 3 4 5 6 7 Eng Design Mix Design Relative cost ofStrength Strength: F′cr, psi $CM/CYD $CM Variance Ref# F′c, psi SD, psiEq [1] Eq [2] Eq [9] per 100 psi SD DEL_$CM/cyd 1 4,000 200 4,268 3,966$24.01 $0.00 $0.00 2 4,000 300 4,402 4,199 $24.76 $0.75 $0.75 3 4,000400 4,536 4,432 $25.52 $0.75 $1.51 4 4,000 500 4,670 4,665 $26.27 $0.75$2.26 5 4,000 600 4,804 4,898 $27.55 $1.28 $3.54 6 4,000 700 4,938 5,131$28.86 $1.31 $4.85 7 4,000 800 5,072 5,364 $30.17 $1.31 $6.17 8 4,000900 5,206 5,597 $31.48 $1.31 $7.48 9 4,000 1,000 5,340 5,830 $32.79$1.31 $8.79

Set forth below is a discussion of real-time batch data variability withrespect to mixture design factors (as specified in a formulation, forexample). Hypothetical data are used to illustrate a quantification ofthe cost of strength performance variably as driven by batchingvariability.

Example Quantification of Batching Data Variability

Table 2 sets forth a set of real time data in columns 1-5. Column 6shows the computed standard deviation W/CM using the raw data fromcolumns 3 and 5.

In the example of Table 2, production facility (plant) #141, representedby row 9, is designated as the benchmark production facility (plant)because it shows the least variability.

TABLE 2 Example Quantification of Strength Standard Deviation due toBatching Variability, and the Resulting Cost Ref# 1 2 3 4 5 6 Measuredfrom CLI batch analysis Eq [6] - Del_CM % Del_WATER % data [A] & [B]Period FROM MIX FROM MIX STDEV W/CM Table [1] Volume, [A] [B] [C] Ref #PLANT cyds AVG DELTA SDrCM AVG DELTA SDrW SDrWCM 1 121 5,500 0.10% 0.50%−22.00% 3.60% 3.6% 2 122 3,000 0.11% 0.68% −3.60% 5.40% 5.4% 3 124 6,800−22.30% 8.20% −14.00% 8.00% 11.5% 4 128 2,000 0.85% 1.58% −10.00% 4.50%4.8% 5 131 8,990 −0.49% 0.33% −13.70% 6.00% 6.0% 6 135 6,000 −0.33%0.59% −7.40% 2.10% 2.2% 7 138 2,500 −0.08% 0.56% −11.00% 5.30% 5.3% 8140 9,850 −0.33% 0.40% −8.70% 11.60% 11.6% 9 141 6,780 −0.16% 0.70%−12.40% 2.00% 2.1% 10 142 4,560 −0.09% 0.23% −9.60% 3.60% 3.6% 11 1437,860 0.34% 0.71% −20.20% 6.00% 6.0% 12 146 3,450 1.26% 4.08% −13.80%6.60% 7.8% 13 147 5,450 2.20% 1.82% −14.60% 2.10% 2.8% 14 150 9,5400.41% 1.71% −11.00% 9.20% 9.4%

Assuming an average concrete mix design strength of 4,000 psi, Table 3shows the strength SD (Column 3) computed from the SD of W/Cm; thestrength SD varies by more than a factor of 5 from 85 psi for thebenchmark plant to 458 psi in plant #124 (row 3). If this batchingstrength SD were reduced to the benchmark value, then significant CMcosts would be saved as shown in column 4; this cost factor varies from$0.02 per cyd to $2.85 due to the varying batching qualities of theproduction facilities.

Supposing that the mix designs (formulations) developed for thebenchmark plant (production facility) are used across all the productionfacilities, this could lead to a very costly situation, sinceprobability analysis shows that for each 100 psi increase in strength SDfrom its assumed mix design value, the failure rate will increase bymore than 4%, which translates to a potential remedial cost of around$2/cyd per 100 psi of SD increase.

TABLE 3 Closed Loop W/CM Ratio & Batching Strength Standard DeviationsFrom Real Time Data Ref# 1 2 3 4 Computed from batch data for avgstrength Computed per of 4,000 psi Table [1] Batching Period STDEV W/CMStrength SD Bench Mark Table [2] Volume, [C] [D] Savings Ref # PLANTcyds SDrWCM SD(Del_S) [E] 1 121 5,500 3.6% 145 $0.45 2 122 3,000 5.4%218 $1.00 3 124 6,800 11.5% 458 $2.80 4 128 2,000 4.8% 191 $0.80 5 1318,990 6.0% 240 $1.17 6 135 6,000 2.2% 87 $0.02 7 138 2,500 5.3% 213$0.96 8 140 9,850 11.6% 464 $2.85 9 141 6,780 2.1% 85 $0.00 10 142 4,5603.6% 144 $0.45 11 143 7,860 6.0% 242 $1.18 12 146 3,450 7.8% 310 $1.6913 147 5,450 2.8% 111 $0.20 14 150 9,540 9.4% 374 $2.17 AVG/YCD $1.21

In various embodiments, the method steps described herein, including themethod steps described in FIGS. 2, 3, 4, 5, 6, 9, 12, 13A-13B, 16A-16B,17, 18, and/or 19A-19B, may be performed in an order different from theparticular order described or shown. In other embodiments, other stepsmay be provided, or steps may be eliminated, from the described methods.

Systems, apparatus, and methods described herein may be implementedusing digital circuitry, or using one or more computers using well-knowncomputer processors, memory units, storage devices, computer software,and other components. Typically, a computer includes a processor forexecuting instructions and one or more memories for storing instructionsand data. A computer may also include, or be coupled to, one or moremass storage devices, such as one or more magnetic disks, internal harddisks and removable disks, magneto-optical disks, optical disks, etc.

Systems, apparatus, and methods described herein may be implementedusing computers operating in a client-server relationship. Typically, insuch a system, the client computers are located remotely from the servercomputer and interact via a network. The client-server relationship maybe defined and controlled by computer programs running on the respectiveclient and server computers.

Systems, apparatus, and methods described herein may be used within anetwork-based cloud computing system. In such a network-based cloudcomputing system, a server or another processor that is connected to anetwork communicates with one or more client computers via a network. Aclient computer may communicate with the server via a network browserapplication residing and operating on the client computer, for example.A client computer may store data on the server and access the data viathe network. A client computer may transmit requests for data, orrequests for online services, to the server via the network. The servermay perform requested services and provide data to the clientcomputer(s). The server may also transmit data adapted to cause a clientcomputer to perform a specified function, e.g., to perform acalculation, to display specified data on a screen, etc.

Systems, apparatus, and methods described herein may be implementedusing a computer program product tangibly embodied in an informationcarrier, e.g., in a non-transitory machine-readable storage device, forexecution by a programmable processor; and the method steps describedherein, including one or more of the steps of FIGS. 2, 3, 4, 5, 6, 9,12, 13A-13B, 16A-16B, 17, 18, and/or 19A-19B, may be implemented usingone or more computer programs that are executable by such a processor. Acomputer program is a set of computer program instructions that can beused, directly or indirectly, in a computer to perform a certainactivity or bring about a certain result. A computer program can bewritten in any form of programming language, including compiled orinterpreted languages, and it can be deployed in any form, including asa stand-alone program or as a module, component, subroutine, or otherunit suitable for use in a computing environment.

A high-level block diagram of an exemplary computer that may be used toimplement systems, apparatus and methods described herein is illustratedin FIG. 21. Computer 2100 includes a processor 2101 operatively coupledto a data storage device 2102 and a memory 2103. Processor 2101 controlsthe overall operation of computer 2100 by executing computer programinstructions that define such operations. The computer programinstructions may be stored in data storage device 2102, or othercomputer readable medium, and loaded into memory 2103 when execution ofthe computer program instructions is desired. Thus, the method steps ofFIG. 2, 3, 4, 5, 6, 9, 12, 13A-13B, 16A-16B, 17, 18, and/or 19A-19B canbe defined by the computer program instructions stored in memory 2103and/or data storage device 2102 and controlled by the processor 2101executing the computer program instructions. For example, the computerprogram instructions can be implemented as computer executable codeprogrammed by one skilled in the art to perform an algorithm defined bythe method steps of FIGS. 2, 3, 4, 5, 6, 9, 12, 13A-13B, 16A-16B, 17,18, and/or 19A-19B. Accordingly, by executing the computer programinstructions, the processor 2101 executes an algorithm defined by themethod steps of FIGS. 2, 3, 4, 5, 6, 9, 12, 13A-13B, 16A-16B, 17, 18,and/or 19A-19B. Computer 2100 also includes one or more networkinterfaces 2104 for communicating with other devices via a network.Computer 2100 also includes one or more input/output devices 2105 thatenable user interaction with computer 2100 (e.g., display, keyboard,mouse, speakers, buttons, etc.).

Processor 2101 may include both general and special purposemicroprocessors, and may be the sole processor or one of multipleprocessors of computer 2100. Processor 2101 may include one or morecentral processing units (CPUs), for example. Processor 2101, datastorage device 2102, and/or memory 2103 may include, be supplemented by,or incorporated in, one or more application-specific integrated circuits(ASICs) and/or one or more field programmable gate arrays (FPGAs).

Data storage device 2102 and memory 2103 each include a tangiblenon-transitory computer readable storage medium. Data storage device2102, and memory 2103, may each include high-speed random access memory,such as dynamic random access memory (DRAM), static random access memory(SRAM), double data rate synchronous dynamic random access memory (DDRRAM), or other random access solid state memory devices, and may includenon-volatile memory, such as one or more magnetic disk storage devicessuch as internal hard disks and removable disks, magneto-optical diskstorage devices, optical disk storage devices, flash memory devices,semiconductor memory devices, such as erasable programmable read-onlymemory (EPROM), electrically erasable programmable read-only memory(EEPROM), compact disc read-only memory (CD-ROM), digital versatile discread-only memory (DVD-ROM) disks, or other non-volatile solid statestorage devices.

Input/output devices 2105 may include peripherals, such as a printer,scanner, display screen, etc. For example, input/output devices 2105 mayinclude a display device such as a cathode ray tube (CRT) or liquidcrystal display (LCD) monitor for displaying information to the user, akeyboard, and a pointing device such as a mouse or a trackball by whichthe user can provide input to computer 2100.

Any or all of the systems and apparatus discussed herein, includingmaster database module 11, input module 12, sales module 13, productionmodule 14, transport module 15, site module 16, alert module 17,purchase module 18, and localization module 19, and components thereof,including mixture database 801 and local factors database 802, may beimplemented using a computer such as computer 2100.

One skilled in the art will recognize that an implementation of anactual computer or computer system may have other structures and maycontain other components as well, and that FIG. 21 is a high levelrepresentation of some of the components of such a computer forillustrative purposes.

The foregoing Detailed Description is to be understood as being in everyrespect illustrative and exemplary, but not restrictive, and the scopeof the invention disclosed herein is not to be determined from theDetailed Description, but rather from the claims as interpretedaccording to the full breadth permitted by the patent laws. It is to beunderstood that the embodiments shown and described herein are onlyillustrative of the principles of the present invention and that variousmodifications may be implemented by those skilled in the art withoutdeparting from the scope and spirit of the invention. Those skilled inthe art could implement various other feature combinations withoutdeparting from the scope and spirit of the invention.

1. A quality control management system comprising: a database modulehaving stored therein a formulation, a first tolerance and a secondtolerance, the first tolerance associated with a first alert and thesecond tolerance associated with a second alert; an input module incommunication with the database module and configured to transmit theformulation, the first tolerance and the second tolerance to thedatabase module; a production module in communication with the databasemodule, the production module associated with a production facility thatmakes a mixture based on the formulation and configured to communicatethe mixture to the database module; a comparison module in communicationwith the database module, and configured to: compare the mixture to theformulation and determine whether the mixture is within the firsttolerance and determine whether the mixture is within the secondtolerance; and an alerts module configured to generate the first alertif the mixture is not within the first tolerance and generate the secondalert if the mixture is not within the second tolerance.
 2. The systemof claim 1, wherein: the database module, the comparison module and thealerts module are housed in a master module in a first computer at afirst location.
 3. The system of claim 2, wherein: the input module ishoused in a second computer at a second location.
 4. The system of claim3, wherein: the production module is housed in a third computer at theconcrete production facility.
 5. The system of claim 1, furthercomprising: a single database module, a plurality of formulations, aplurality of production modules each associated with a differentproduction facility, a single comparative module and a single alertsmodule.
 6. The system of claim 1, wherein the mixture is one of aconcrete mixture, a chemical compound, a chemical-based product, apetroleum-based product, a food product, and a pharmaceutical drug.
 7. Aquality control management method for concrete, the method comprising:inputting to a database a concrete recipe, a first tolerance forgenerating an informational alert and a second tolerance for generatinga second alert; producing a concrete mixture based on the concreterecipe; inputting to the database the concrete mixture; comparing theconcrete mixture to the concrete recipe; generating the first alert ifthe concrete mixture meets or exceeds the first tolerance; generatingthe second alert if the concrete mixture meets or exceeds the secondtolerance.
 8. The method of claim 7, wherein: the concrete recipespecifies first ingredients, first amounts of the first ingredients, andfirst costs of the first ingredients; and the concrete mixture specifiessecond ingredients in the concrete mixture produced, second amounts ofthe second ingredients and second costs of the second ingredients. 9.The method of claim 8, further comprising: comparing the secondingredients to the first ingredients, comparing the second amounts tothe first amounts, and comparing the second costs to the first costs.10. A closed loop system for use in a production system comprising aplurality of production facilities: a plurality of formulations storedin the database, each formulation specifying a plurality of componentsand a plurality of corresponding quantities; a production moduleassociated with a production facility, the production module configuredto transmit batch data indicating batched components and batchedquantities associated with a batch of a concrete mixtures after thebatch has been produced based on a particular formulation specifyingparticular components and particular quantities; a second moduleconfigured to transmit the batch data to the database; a comparisonmodule configured to: compare, for each batched component, a batchedquantity Xb to a corresponding particular quantity Xm specified in theparticular formulation; and calculate, for each batched component, avalue ΔX=(Xb−Xm)/Xm.
 11. The closed loop system of claim 10, wherein thecomparison module is further configured to: compare, for each batchedcomponent, a batched cost $Xb to a corresponding particular cost $Xmassociated with the particular formulation; and calculate, for eachbatched component, a cost value 4$X=($Xb−$Xm)/$Xm.
 12. A methodcomprising: performing the following operations for each of a pluralityof production facilities: determining, for each of a plurality ofbatches of a concrete mixture produced at the respective productionfacility based on a formulation, a first difference between a measuredquantity of cementitious and a first quantity specified in theformulation; determining a first standard deviation based on the firstdifferences; determining, for each of the plurality of batches, a seconddifference between a measured quantity of water and a second quantityspecified in the formulation; and determining a second standarddeviation based on the second differences; selecting a first benchmarkfrom among the first standard deviations; selecting a second benchmarkfrom among the second standard deviations; and determining an amount bywhich costs may be reduced by improving production at the productionfacility to meet the first and second benchmarks.
 13. The method ofclaim 12, further comprising: storing the formulation at a masterdatabase module; and providing a localized version of the formulation toeach respective production facility.
 14. The method of claim 12, whereinthe plurality of production facilities are managed by a producer, themethod further comprising: allowing the producer to access, via anetwork, a page showing the first differences, the second differences,the first benchmark, the second benchmark, and the amount by which costsmay be reduced.
 15. The method of claim 12, further comprising: for eachof the plurality of production facilities: determining a firstpercentage value equal to first difference divided by the first quantityspecified in a formulation; determining a first standard deviation basedon the first percentage values; determining a second percentage valueequal to second difference divided by the second quantity specified in aformulation; and determining a second standard deviation based on thesecond percentage values.
 16. The method of claim 12, furthercomprising: determining a generalized benchmark based on the first andsecond benchmarks.
 17. The method of claim 16, further comprising:determining an amount by which costs may be reduced by improvingproduction at the production facility to meet the generalized benchmark.18. A method comprising: transmitting to a production facility, inresponse to receiving an order for a product from a customer, aformulation associated with the product, the formulation specifying aplurality of components and respective quantities required to producethe product; receiving, in real time, data relating to the productproduced at the production facility; comparing, in real time, the datato at least one pre-established tolerance; and transmitting, in realtime, an alert to the customer if the data is not within thepre-established tolerance.
 19. The method of claim 18, furthercomprising: delivering the product to a site specified by the customer.20. The method of claim 18, further comprising: determining a differencebetween a quantity of a component specified in the formulation and anactual quantity of the component in the product produced; anddetermining if the difference is within the tolerance.
 21. The method ofclaim 18, further comprising: determining a difference between a cost ofa component specified in the formulation and a cost of the component inthe product produced; and determining if the difference is within thetolerance.
 22. The method of claim 18, wherein the product is one of aconcrete mixture, a chemical compound, a chemical-based product, apetroleum-based product, a food product, and a pharmaceutical drug. 23.A method of determining a measure of concrete strength performancequality for concrete produced at a production facility, the methodcomprising: determining, for each of a plurality of batches of concreteproduced at a production facility, a first difference between a measuredquantity of cementitious and a first quantity specified in aformulation; determining a first standard deviation based on the firstdifferences; determining, for each of the plurality of batches, a seconddifference between a measured quantity of water and a second quantityspecified in the formulation; determining a second standard deviationbased on the second differences; determining a measure of concretestrength performance quality for the production facility based on thefirst standard deviation and the second standard deviation; anddetermining a measure of a cost of adjusting the formulation based onthe measure of concrete strength performance quality.